We found this to be a race condition supposedly within aufs. The script
that mounts the overlay does the following:

# perform the aufs root mount
modprobe aufs
mount -t aufs -o br:${localroot}=rw:${netroot}=nfsro aufsroot ${rootmnt}

Doing this results in the described problem - df reports 0 bytes free on
${rootmnt}.

The fix is rather easy while a little annoying:

# perform the aufs root mount
modprobe aufs
# wait a second to avoid a race condition; see 
https://bugs.launchpad.net/bugs/382842
sleep 1
mount -t aufs -o br:${localroot}=rw:${netroot}=nfsro aufsroot ${rootmnt}

This all happens within the initrd, by the way.

Perhaps this should be documented somewhere.

-- 
aufs fails to report free space when the readonly-branch comes via nfs and the 
readwrite-branch via a local ext3
https://bugs.launchpad.net/bugs/382842
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