In this case, the problem is somewhat unrelated: The partitions don't seem to
fit on disk in this way. That is, there isn't sufficient space for 512 * 1024 *
1024 bytes before sda2.

Was that layout created using setup-storage? Probably yes. What I do suspect is
some rounding issue, and, well this is the culprit: The partition has been
created such as to end at a cylinder boundary, which is considered for the final
disk layout, but not for intermediate checks.

My mistake, sorry.

I built the filesystem with setup-storage, using version FAI version 3.3.4 and for sda1 a size of '512', with no unit. And then ran 3.3.5-experimental2 to resize /usr, with the same size of '512' for sda1, which seems to give a different result.

I have done it again using a size of 512MiB, and it works as expected: the volume is resized, but the filesystem is not.

--
Nicolas

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