Hi Steve,

> > I am attempting to reproduce from your script.
> 
> OK I have reproduced the problem. It appears that the directory withing 
> the IMG is empty and yet the file is quite large, so something is very 
> wrong.

Can you add some diagnostics for this case?  Preferrably near the place
where the overflow is about to occur.  It would also be nice if mkgmap
complained about the missing TRE header.  Currently it is omitting the
offending tile without warning.

I got it to work by moving the tile border south from
lat=2916352 to lat=2899968:

-rw-r--r-- 1 marko marko 26660864 19.1. 13:45 63240001.img
-rw-r--r-- 1 marko marko 11357184 19.1. 13:45 63240002.img
-rw-r--r-- 1 marko marko  7699968 19.1. 13:45 63240003.img

+63240001: 2768896,890880 to 2899968,1472512
+#       : 59.414063,19.116211 to 62.226562,31.596680
+63240002: 2899968,890880 to 3020800,1472512
+#       : 62.226562,19.116211 to 64.819336,31.596680

By the way, I tried to merge the '2 and '3 tiles a few weeks ago,
but split them again because a routing test failed.  Tile '1 is
biggest and growing fastest, because most population and map
features are located there.

Best regards,

        Marko
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