Seems to be related to the size and/or position of the LV on disk or
partitioning setup inside the LV.  1TB drives (software RAID 1) with LBA
enabled.

4 GB LV, 2 GB root, 2GB swap:

test01.txt:2010-07-28 13:39:00,848 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test02.txt:2010-07-28 13:40:32,217 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test03.txt:2010-07-28 13:42:08,167 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test04.txt:2010-07-28 13:43:46,199 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test05.txt:2010-07-28 13:45:20,067 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test06.txt:2010-07-28 13:46:53,004 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test07.txt:2010-07-28 13:48:25,589 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test08.txt:2010-07-28 13:49:56,128 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test09.txt:2010-07-28 13:51:27,426 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test10.txt:2010-07-28 13:53:00,229 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes

40 GB LV, 32 GB root, 8 GB swap:

test11.txt:2010-07-28 13:55:45,188 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test12.txt:2010-07-28 13:57:23,889 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test13.txt:2010-07-28 13:59:04,599 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test14.txt:2010-07-28 14:00:43,285 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test15.txt:2010-07-28 14:02:25,818 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test16.txt:2010-07-28 14:04:04,428 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test17.txt:2010-07-28 14:05:46,409 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test18.txt:2010-07-28 14:07:26,049 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... no
test19.txt:2010-07-28 14:09:08,828 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test20.txt:2010-07-28 14:10:48,468 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes

10 GB LV, 8 GB root, 2 GB swap:


test21.txt:2010-07-28 14:14:40,718 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test22.txt:2010-07-28 14:16:20,228 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... no
test23.txt:2010-07-28 14:17:59,287 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... no
test24.txt:2010-07-28 14:19:37,439 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test25.txt:2010-07-28 14:21:12,338 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... no
test26.txt:2010-07-28 14:22:51,709 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... no
test27.txt:2010-07-28 14:24:26,248 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test28.txt:2010-07-28 14:26:02,670 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test29.txt:2010-07-28 14:27:36,028 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes
test30.txt:2010-07-28 14:29:12,604 DEBUG   :  Checking if "/boot/grub/stage1" 
exists... yes

-- 
vmbuilder randomly fails to install grub
https://bugs.launchpad.net/bugs/610652
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