Thanks Gerd, 
My old ovm_* files were 236 MB. I havent created new img tiles yet with r3595. 
If I run mkgmap on the old img files the same error is thrown out so I assume I 
must compile the tiles again. 
I'll report it here later today because whole europe will take some time. 

> shapes turned out to be simple, with r3592 the overview map
> file size is again smaller, esp. when the map contains
> sea or forest polygons.
> The ratio depends on the style, the 30% below were for the default
> style which adds motorways.
> For a map of Ireland, I see now 98KB with r3592 and 142KB with r3590,
> both with "Openfietsmap full" style.

> Gerd
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