The only time i've experienced actually running out of space, it's pretty obvious either in the buildimgfs or addfile stage and I get a popup stating the program has stopped working in Vista or memory reference error in XP.
This actually makes me wonder some especially with this apparent abundance of usable space on our devices, why it's not better optimized by the carriers. My i730 basically only allows less then 5 MB of files to be added before you hit the ceiling and they don't have the audible or other junk in their image.
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