According to this in image.bbclass, the rootfs size should be IMAGE_ROOTFS_SIZE unless the actual size * (IMAGE_OVERHEAD_FACTOR = 1.2) is greater than that. The IMAGE_ROOTFS_SIZE used in the comparison doesn't take the value of IMAGE_ROOTFS_SIZE_ext3 when used, as it seems it should: ROOTFS_SIZE=`du -ks ${IMAGE_ROOTFS}|awk '{size = $1 * ${IMAGE_OVERHEAD_FACTOR}; print (size > ${IMAGE_ROOTFS_SIZE} ? size : ${IMAGE_ROOTFS_SIZE}) }'` So IMAGE_ROOTFS_SIZE_ext3 seems to be getting ignored - the only way I was able to get a 1G image was to use the straight IMAGE_ROOTFS_SIZE e.g. using IMAGE_ROOTFS_SIZE ?= "1000000" instead of IMAGE_ROOTFS_SIZE_ext3 = "1000000" in emenlow.conf. Here are the image sizes with IMAGE_ROOTFS_SIZE_ext3: -rw-r--r-- 1 trz trz 582105088 2011-03-22 01:58 poky-image-sato-live-emenlow-20110322065226.hddimg -rw-r--r-- 1 trz trz 581939200 2011-03-22 01:58 poky-image-sato-live-emenlow-20110322065226.iso Here are the image sizes with plain IMAGE_ROOTFS_SIZE: -rw-r--r-- 1 trz trz 1032947712 2011-03-22 02:21 poky-image-sato-live-emenlow-20110322071321.hddimg -rw-r--r-- 1 trz trz 1032779776 2011-03-22 02:21 poky-image-sato-live-emenlow-20110322071321.iso The same thing is probably true of the other variants too e.g. IMAGE_ROOTFS_SIZE_ext2 but I haven't tried those.
Fixed in master in http://git.yoctoproject.org/cgit.cgi/poky/commit/?id=adac5a690fd5b4239bb59ec54e3e5174dbcf29e9