You may have large files with "holes" in them (i.e. sparse files).  Rsync has a --sparse (-S) flag that tries to create holes in the replicated files when it finds sequences of nulls in the source file.

The -a flag does not turn on this sparse file handling.

You can run "du" on different directories to narrow down where the file size difference is coming from.

    - Aner

On 3/29/22 10:58, F Bax wrote:
I used rsync to copy files.
sudo rsync -anv --delete /mnt/wd1l/ /mnt/wd2l/
reports no changes required (runtime under 3 minutes).
sudo diff -r /mnt/wd1l/ /mnt/wd2l/
reports no difference (runtime 10 hours)

$ sudo df -i /mnt/wd1l/ /mnt/wd2l/
Filesystem  512-blocks      Used     Avail Capacity iused   ifree  %iused
  Mounted on
/dev/wd1l   2138940784 1997329632  34664128    98%  483707 33313411     1%
   /mnt/wd1l
/dev/wd2l   2138951776 2033043696  -1039504   100%  483707 33313411     1%
   /mnt/wd2l

On Tue, Mar 29, 2022 at 10:49 AM F Bax <fbax...@gmail.com> wrote:

I used rsync to copy files. df -i reports 483707 inodes used for both
partitions.
sudo rsync -anv --delete /mnt/wd1l/ /mnt/wd2l/
reports no changes required (runtime under 3 minutes).
sudo diff -r /mnt/wd1l/ /mnt/wd2l/
reports no difference (runtime 10 hours)

On Tue, Mar 29, 2022 at 10:39 AM Otto Moerbeek <o...@drijf.net> wrote:

On Tue, Mar 29, 2022 at 10:25:34AM -0400, F Bax wrote:

I copied all files from /mnt/wd1l to /mnt/wd2l

wd2l is slightly larger than wd1l; yet wd2l is full!

$ df -h /mnt/wd1l /mnt/wd2l
Filesystem Size Used Avail Capacity Mounted on
/dev/wd1l 1020G 952G 16.5G 98% /mnt/wd1l
/dev/wd2l 1020G 969G -508M 100% /mnt/wd2l
How did you copy? Some forms of copy will cause hardlinked files to be
separate files on the destination. df -i will tell how many inodes you
have used. If wd2l has more inodes in use, I bet it's that.

         -Otto

Output from disklabel is almost identical:

type: SCSI
disk: SCSI disk
label: WDC WD2000FYYZ-0
flags:
bytes/sector: 512
sectors/track: 63
tracks/cylinder: 255
sectors/cylinder: 16065
cylinders: 243201
total sectors: 3907029168
rpm: 0
interleave: 1
trackskew: 0
cylinderskew: 0
headswitch: 0 # microseconds
track-to-track seek: 3907029168 # microseconds
drivedata: 0

Difference between wd1 and wd2:
wd1: interleave: 0
wd2: interleave: 1

Partition details (A added 'wd1/wd2' to beginning of line:
# size offset fstype [fsize bsize cpg]
wd1l: 2147472640 525486208 4.2BSD 8192 65536 1
wd2l: 2147483647 63 4.2BSD 8192 65536 1

  Why is wd2l full?

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