For the wic tool, with large images, for example sdk images, populate-extfs.sh produces the same kind of output as seen here: https://lists.yoctoproject.org/pipermail/yocto/2013-November/017420.html e.g.: Allocated inode: 15264 copy_file: Could not allocate block in ext2 filesystem debugfs: sif "libgio-2.0.so.0.3800.1" mode 0x81ed The below says it is a problem with e2fsprogs and would be fixed, but it doesn't appear it was fixed, and there's no bug report for it: https://lists.yoctoproject.org/pipermail/yocto/2013-November/017448.html
We use the "mke2fs -d" to instead of populate-extfs.sh to fix this issue: http://git.yoctoproject.org/cgit/cgit.cgi/poky/commit/?id=5809ce0c895ddb96c4b1dd4c87ebd85dfbe5c1a0