I hope to have addressed all the above problems in 4.0~beta2+experimental48. Could you please give that one another try and report back? Could you please even send debug logs in case it works fine? As said in the other thread just
moments ago, I'm trying to to a bit of cleanup work as well.

This new version does fix the issue, thanks. I send you the format.log in a private mail.


Well well, I finally happen to have another problem with this new version, setup-storage prints the following sentence and then quits quickly:

Executing: mdadm --examine --scan --verbose -c partitions
Previous partitions overflow begin of preserved partition /dev/sda2

I tried several values for the /local volume, but always get the same message. Here's the debug format.log, which happens to be pretty short.

--
Nicolas
Starting setup-storage 1.3+exp
disklist: sda
Using config file: /var/lib/fai/config/disk_config/auzon
Input was:
# Configuration LVM standard : les partitions sont extensibles
disk_config disk1
primary		/boot		 512	ext3	rw
primary		-	       32000-	-	-

disk_config lvm fstabkey:uuid preserve_reinstall:vg0-local
#disk_config lvm fstabkey:uuid
vg vg0 disk1.2
vg0-swap    swap            2GiB    swap    sw
vg0-root    /               1GiB    ext3    rw
vg0-var     /var            4GiB    ext3    rw
vg0-usr     /usr            8GiB    ext3    rw
vg0-opt     /opt            2GiB    ext3    rw
vg0-local   /local          20GiB-  ext3    rw
(CMD) parted -s /dev/sda unit TiB print 1> /tmp/VoENpO9GP9 2> /tmp/iAyirJMaGs
Executing: parted -s /dev/sda unit TiB print
(STDOUT) Model: ATA WDC WD1600AAJS-6 (scsi)
(STDOUT) Disk /dev/sda: 0.15TiB
(STDOUT) Sector size (logical/physical): 512B/512B
(STDOUT) Partition Table: msdos
(STDOUT) 
(STDOUT) Number  Start    End      Size     Type     File system  Flags
(STDOUT)  1      0.00TiB  0.00TiB  0.00TiB  primary  ext3         boot
(STDOUT)  2      0.00TiB  0.15TiB  0.15TiB  primary               lvm
(STDOUT) 
(CMD) parted -s /dev/sda unit B print free 1> /tmp/eKm1feG9g2 2> /tmp/QoiYnqPQxE
Executing: parted -s /dev/sda unit B print free
(STDOUT) Model: ATA WDC WD1600AAJS-6 (scsi)
(STDOUT) Disk /dev/sda: 160041885696B
(STDOUT) Sector size (logical/physical): 512B/512B
(STDOUT) Partition Table: msdos
(STDOUT) 
(STDOUT) Number  Start          End            Size           Type     File system  Flags
(STDOUT)  1      32256B         534643199B     534610944B     primary  ext3         boot
(STDOUT)  2      534643200B     160039272959B  159504629760B  primary               lvm
(STDOUT)         160039272960B  160041885695B  2612736B                Free Space
(STDOUT) 
(CMD) parted -s /dev/sda unit chs print free 1> /tmp/ECQg6UZJU_ 2> /tmp/P1410qoz1z
Executing: parted -s /dev/sda unit chs print free
(STDOUT) Model: ATA WDC WD1600AAJS-6 (scsi)
(STDOUT) Disk /dev/sda: 19457,80,62
(STDOUT) Sector size (logical/physical): 512B/512B
(STDOUT) BIOS cylinder,head,sector geometry: 19457,255,63.  Each cylinder is 8225kB.
(STDOUT) Partition Table: msdos
(STDOUT) 
(STDOUT) Number  Start      End           Type     File system  Flags
(STDOUT)  1      0,1,0      64,254,62     primary  ext3         boot
(STDOUT)  2      65,0,0     19456,254,62  primary               lvm
(STDOUT)         19457,0,0  19457,80,62            Free Space
(STDOUT) 
    Finding all volume groups
    Finding volume group "vg0"
    Creating directory "/etc/lvm/archive"
    Archiving volume group "vg0" metadata (seqno 11).
    Creating directory "/etc/lvm/backup"
    Creating volume group backup "/etc/lvm/backup/vg0" (seqno 11).
    Finding all volume groups
    Finding volume group "vg0"
    Finding all volume groups
    Finding volume group "vg0"
    Finding all volume groups
    Finding volume group "vg0"
(CMD) mdadm --examine --scan --verbose -c partitions 1> /tmp/JPF0vBUYns 2> /tmp/jxNtkFqh_Z
Executing: mdadm --examine --scan --verbose -c partitions
Previous partitions overflow begin of preserved partition /dev/sda2
Current disk layout
$VAR1 = {
          '/dev/sda' => {
                          'bios_heads' => '255',
                          'disklabel' => 'msdos',
                          'partitions' => {
                                            '1' => {
                                                     'count_byte' => '534610944',
                                                     'filesystem' => 'ext3',
                                                     'begin_byte' => '32256',
                                                     'is_extended' => 0,
                                                     'end_byte' => '534643199'
                                                   },
                                            '2' => {
                                                     'count_byte' => '159504629760',
                                                     'filesystem' => '',
                                                     'begin_byte' => '534643200',
                                                     'is_extended' => 0,
                                                     'end_byte' => '160039272959'
                                                   }
                                          },
                          'bios_cylinders' => '19457',
                          'size' => '160041885696',
                          'sector_size' => '512',
                          'begin_byte' => 0,
                          'end_byte' => '160041885695',
                          'bios_sectors_per_track' => '63'
                        }
        };
Current LVM layout
$VAR1 = {
          'vg0' => {
                     'volumes' => {
                                    'var' => {
                                               'size' => '2048'
                                             },
                                    'swap' => {
                                                'size' => '2048'
                                              },
                                    'root' => {
                                                'size' => '1024'
                                              },
                                    'opt' => {
                                               'size' => '2048'
                                             },
                                    'usr' => {
                                               'size' => '6144'
                                             },
                                    'local' => {
                                                 'size' => '40960'
                                               }
                                  },
                     'physical_volumes' => [
                                             '/dev/sda2'
                                           ],
                     'size' => '152115.2'
                   }
        };
Current RAID layout
$VAR1 = {};

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