Is there a way to limit VFAT allocation?

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Hi,

I have bought a 2GB MP3 player / flash disk
that erroneously partitions and formats its storage.
The built-in firmware has an off-by-one bug that
creates the partition one cylinder larger that the
disk size allows and then it formats the VFAT fs
according to the buggy partition size. No wonder
when I try to copy large amounts of data to the
flash disk it detects errors and then remounts it
read-only.

I tried to repartition and reformat it three times
with different mformat or mkdosfs options
but as soon as I remove it from the USB port,
the device detects changed disk format and
automatically reformats itself again, so it
stays buggy.

Here's the excerpt from the logs on one occasion
I tried to copy some large stuff onto it:
Oct 3 22:56:31 host-81-17-177-202 kernel: SCSI device sdb: 4095765 512-byte hdwr sectors (2097 MB) 
Oct  3 22:56:31 host-81-17-177-202 kernel: sdb: Write Protect is off
Oct 3 22:56:32 host-81-17-177-202 kernel: sdb: assuming drive cache: write through Oct 3 22:56:32 host-81-17-177-202 kernel: SCSI device sdb: 4095765 512-byte hdwr sectors (2097 MB) 
Oct  3 22:56:32 host-81-17-177-202 kernel: sdb: Write Protect is off
Oct 3 22:56:32 host-81-17-177-202 kernel: sdb: assuming drive cache: write through 
Oct  3 22:56:33 host-81-17-177-202 kernel:  sdb: sdb1
Oct  3 22:56:33 host-81-17-177-202 kernel:  sdb: p1 exceeds device capacity
Oct 3 22:56:33 host-81-17-177-202 kernel: sd 6:0:0:0: Attached scsi removable disk sdb Oct 3 22:56:33 host-81-17-177-202 kernel: sd 6:0:0:0: Attached scsi generic sg1 type 0 Oct 3 22:56:33 host-81-17-177-202 kernel: sd 5:0:0:0: Attached scsi removable disk sdc Oct 3 22:56:33 host-81-17-177-202 kernel: sd 5:0:0:0: Attached scsi generic sg2 type 0 Oct 3 22:56:33 host-81-17-177-202 kernel: Buffer I/O error on device sdb1, logical block 4095616 Oct 3 22:56:34 host-81-17-177-202 kernel: Buffer I/O error on device sdb1, logical block 4095617 Oct 3 22:56:34 host-81-17-177-202 kernel: Buffer I/O error on device sdb1, logical block 4095618 Oct 3 22:56:34 host-81-17-177-202 kernel: Buffer I/O error on device sdb1, logical block 4095619 Oct 3 22:56:34 host-81-17-177-202 kernel: Buffer I/O error on device sdb1, logical block 4095620 Oct 3 22:56:34 host-81-17-177-202 kernel: Buffer I/O error on device sdb1, logical block 4095621 Oct 3 22:56:34 host-81-17-177-202 kernel: Buffer I/O error on device sdb1, logical block 4095622 Oct 3 22:56:34 host-81-17-177-202 kernel: Buffer I/O error on device sdb1, logical block 4095623 Oct 3 22:56:34 host-81-17-177-202 kernel: Buffer I/O error on device sdb1, logical block 4095616 Oct 3 22:56:34 host-81-17-177-202 kernel: Buffer I/O error on device sdb1, logical block 4095617 Oct 3 22:56:34 host-81-17-177-202 kernel: SELinux: initialized (dev sdb1, type vfat), uses genfs_contexts 
...
Oct  3 23:26:53 host-81-17-177-202 kernel: FAT: Filesystem panic (dev sdb1)
Oct 3 23:26:53 host-81-17-177-202 kernel: fat_get_cluster: invalid cluster chain (i_pos 0) Oct 3 23:26:53 host-81-17-177-202 kernel: File system has been set read-only 
...
Oct  3 23:31:35 host-81-17-177-202 kernel: FAT: Filesystem panic (dev sdb1)
Oct 3 23:31:35 host-81-17-177-202 kernel: fat_get_cluster: invalid cluster chain (i_pos 0) 
Oct  3 23:35:33 host-81-17-177-202 kernel: FAT: Filesystem panic (dev sdb1)
Oct 3 23:35:33 host-81-17-177-202 kernel: fat_bmap_cluster: request beyond EOF (i_pos 47395744) 
Oct  3 23:35:33 host-81-17-177-202 kernel: FAT: Filesystem panic (dev sdb1)
Oct 3 23:35:33 host-81-17-177-202 kernel: fat_bmap_cluster: request beyond EOF (i_pos 47395744) 
Oct  3 23:35:33 host-81-17-177-202 kernel: FAT: Filesystem panic (dev sdb1)
Oct 3 23:35:33 host-81-17-177-202 kernel: fat_bmap_cluster: request beyond EOF (i_pos 47395744) 
Oct  3 23:35:33 host-81-17-177-202 kernel: FAT: Filesystem panic (dev sdb1)
Oct 3 23:35:33 host-81-17-177-202 kernel: fat_bmap_cluster: request beyond EOF (i_pos 47395744) 
...

Unfortunately, the firmware is not upgradeable.
The device in question is a Telstar UFM-102B.

Is there a way to tell the VFAT driver to exclude
the last N sectors from the allocation strategy?

Best regards,
Zoltán Böszörményi

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