As a test, here's the same experiment with a 30MB disk image. Again,
it doesn't work with T2505 USB "Full" but does work with T2505 USB
"Lite":


> $ qemu-img create -f qcow2 small.qcow2 30M


..booting from T2505 USB "Full":

> C:\>fdisk 2 /auto
> C:\>fdisk 2 /info
>
> Current fixed disk drive: 2   60480 sectors, geometry 60/016/63
>
> Partition   Status   Mbytes   System           Usage    Start CHS       End 
> CHS
>  D: 1   4      A         29   FAT-16 <32M       100%     0/001/01     
> 59/015/63
>
> Largest continuous free space for primary partition = 0 MBytes


..rebooting and FORMAT:

> C:\>format D: /D
>
> [DEBUG]  FORMAT 0.92a, selected drive D:
> [DEBUG]  Sector buffer at 15E1:BD3C, track buffer at 15E1:673C
> [DEBUG]  DOS 7+, LOCKing drive
>
>  WARNING: ALL DATA ON NON-REMOVABLE DISK
>  DRIVE D: WILL BE LOST! PLEASE CONFIRM!
> Proceed with Format (YES/NO)?YES
> [DEBUG]  Checking whether UNFORMAT data can be saved.
> [DEBUG]  Test-reading boot sector.
> +*** bad sector(s): 0 (code 0x201) on READ *
>  maybe FAT32?
> **** bad sector(s): 0 (code 0x20C) on READ *
> [DEBUG]  Error code: 0x20C
>   Boot sector unreadable, disk not yet formatted
> [DEBUG]  DOS 7+, FORMAT-LOCKing drive
> [DEBUG]  FAT1x size: 59, using FAT16.
>  Disk size: 29 Mbytes, FAT16. ***
> [DEBUG]  Enabled access flags.
> Cannot find existing format - not saving UNFORMAT data.
> Please enter volume label (max. 11 chars): SMALL
>  QuickFormatting (only flushing metadata)
>  Warning: Resets bad cluster marks if any.
> [DEBUG]  File System Creation
> [DEBUG]  Boot Sector -> 0
> +**Drive_IO(WRITE 0, count 1 ) [FAT12/16] [drive D*]
>
>  Critical error during DOS disk access
>  DOS driver error (hex): 01
>    Description: unknown unit for driver
>  Program terminated.
> [DEBUG]  DOS 7+, UNLOCKing drive (by one level)
> [DEBUG]  DOS 7+, UNLOCKing drive (by one level)


And trying again using T2505 USB "Lite": (recreated a new 30MB disk image)

> C:\>fdisk 2 /auto
> C:\>fdisk 2 /info
>
> Current fixed disk drive: 2   60480 sectors, geometry 60/016/63
>
> Partition   Status   Mbytes   System           Usage    Start CHS       End 
> CHS
>  D: 1   4      A         29   FAT-16 <32M       100%     0/001/01     
> 59/015/63
>
> Largest continuous free space for primary partition = 0 MBytes


..and rebooting and FORMAT:

> C:\>format D: /D
>
> [DEBUG]  FORMAT 0.92a, selected drive D:
> [DEBUG]  Sector buffer at 15E1:BD3C, track buffer at 15E1:673C
> [DEBUG]  DOS 7+, LOCKing drive
>
>  WARNING: ALL DATA ON NON-REMOVABLE DISK
>  DRIVE D: WILL BE LOST! PLEASE CONFIRM!
> Proceed with Format (YES/NO)?YES
> [DEBUG]  Checking whether UNFORMAT data can be saved.
> [DEBUG]  Test-reading boot sector.
> **** bad sector(s): 0 (code 0x810C) on READ *
>  maybe FAT32?
> **** bad sector(s): 0 (code 0x20C) on READ *
> [DEBUG]  Error code: 0x20C
>   Boot sector unreadable, disk not yet formatted
> [DEBUG]  DOS 7+, FORMAT-LOCKing drive
> [DEBUG]  FAT1x size: 59, using FAT16.
>  Disk size: 29 Mbytes, FAT16. ***
> [DEBUG]  Enabled access flags.
> Cannot find existing format - not saving UNFORMAT data.
> Please enter volume label (max. 11 chars):
>  QuickFormatting (only flushing metadata)
>  Warning: Resets bad cluster marks if any.
> [DEBUG]  File System Creation
> [DEBUG]  Boot Sector -> 0
> [DEBUG]  FAT Sectors: 1 to 118 ->
>   0%  17%  35%  53%  71%  88%  89%  90%  91%  92%  93%  94%  95%  96%  97%  
> 98%
>  99% 100%
> [DEBUG]  FAT1 Start -> 1
> [DEBUG]  FAT2 Start -> 60
> [DEBUG]  Root Directory Sectors: 119 to 150 ... done.
> [DEBUG]  Root, Label, Timestamp -> 119
> [DEBUG]  File System Created
>
> QuickFormat complete.
> [DEBUG]  DOS 7+, UNLOCKing drive (by one level)
> [DEBUG]  DOS 7+, UNLOCKing drive (by one level)
>
>     30,933,504  bytes total disk space (disk size)
>     30,855,168  bytes available on disk (free clusters)
>
>          2,048  bytes in each allocation unit.
>         15,066 allocation units on disk.
>
>  Volume Serial Number is 121F-1EEA



On Sat, May 3, 2025 at 5:54 PM Jim Hall <jh...@freedos.org> wrote:
>
> Hi Eric
>
> On Sat, May 3, 2025 at 5:47 PM Eric Auer via Freedos-devel
> <freedos-devel@lists.sourceforge.net> wrote:
> >
> >
> > Hi Jim,
> >
> > can you check which differences can be found in the FORMAT
> > log when formatting does succeed? If I understand you
> > correctly, things depend on from which drive you boot
> > and / or which KERNEL version you used?
>
> Not correct. The kernel version is the same between FreeDOS 1.4 and
> FreeDOS T2505, so this isn't a kernel issue.
>
> FORMAT is the same version (0.92a) in both FreeDOS 1.4 and FreeDOS
> T2505, so this isn't a FORMAT regression.
>
> > A FAT12 partition with 10k sectors is quite small, do you
> > get similar problems for FAT16 < 32 MB partition type? Or
> > is this a FAT12 specific issue, affecting others < 32 MB?
>
> I haven't tried other disk sizes (yet). I only needed a 5MB disk
> image, so that's the one I used (and found the issue).
>
> > Does the problem depend on which version of the kernel
> > and/or format you use, in other words, could this be a
> > regression? Do things work with EDR-DOS or MS kernels?
>
> I haven't tried it with MS-DOS (and I don't have a copy of EDR-DOS)
> but the FreeDOS kernel is the same version in FreeDOS 1.4 and T2505,
> and the FORMAT version is the same in FreeDOS 1.4 and T2505.


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