Mender-Convert 4.0.2 to 4.3.0 Upgrade Causes 2.5GB Rootfs Size Increase, Is This Expected?

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Hi everyone,

I’m experiencing a significant rootfs size increase after upgrading mender-convert from 4.0.2 to 4.3.0, and I’m trying to understand if this is expected behavior or if something has changed that I’m not aware of.

The Problem:

  • 4.0.2: Rootfs filesystem size was 23,074 MiB
  • 4.3.0: Rootfs filesystem size is now 25,715 MiB (+2.6GB increase)

The 2.5GB increase seems excessive for just a version update.
This causes my conversion to fail with:

[WARN] The calculated rootfs partition size 23224 MiB is too small.
[WARN] The actual rootfs image size is 25715 MiB
[FATAL] You can try adjusting the MENDER_STORAGE_TOTAL_SIZE_MB variable to increase available space

My Setup:

  • Same golden image input (25GB total size in both cases)
  • Identical configuration file
  • Same overlay directory
  • Both runs install the same addons (Connect + Configure)

Questions:

  1. Is this size increase expected when upgrading to mender-convert 4.3.0?
  2. What specifically changed between these versions that could cause such a large increase?
  3. Are there any configuration options I should adjust to maintain the previous behavior?

Has anyone else experienced this issue during the upgrade? Any insights into what changed in mender-convert 4.3.0 that could cause this would be greatly appreciated.

I have attached the detailed logs (log 1708435600-129446 for 4.0.2 and log 1756398228-171055 for 4.3.0) to help with analysis.

1708435600-129446-convert.yaml (45.2 KB)
1756398228-171055-convert.yaml (35.7 KB)
custom_x86-64_hdd_config.yaml (2.4 KB)

Thanks in advanced.