Another update from Stuart regarding mkdosfs/mkfs.vfat that may be
relevant and it may lend some ammo to possibly adding the "-s 1" flag to
the mkdosfs command mentioned above?

"So it looks like mkdosfs / mkfs.vfat is calculating an initial guess
for "bs.cluster_size" (the internal variable name) based on the size of
the disk, just assuming 512 bytes per sector.

The assumption is implicit, because they are using numbers from a table
in a Microsoft document, and the number "512" (or any sort of sectors
per track) doesn't show up in the code here, so that is probably why it
got missed.  They clearly take into account sectors per track elsewhere
in the code.

The code will actually increase the number of sectors in a cluster until
it fits nicely, but it will not decrease it.

I'll try to get a patch in upstream to fix this.  For now, though, it
should work ok to just use "-s 1", as far as I can tell."

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https://bugs.launchpad.net/bugs/1065281

Title:
  Installer crashed when trying to partition 4k/4k sector hard disks

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