[quote="solskogen"]Which makes me think something is wrong on your end, because the rootfs-tarballs haven't been updated since march of 2023.[/quote]
fair enough ... although same operations and *same SD* card ... could it be that bsdtar had an issue and got recently updated/fixed? ... dunno, just sharing I have recently managed to do exact same operations out of exact same procedure and exact same SD cards failing before and suddenly I had zero issues around that same operation that was repeatedly failing a few days ago.