riel, When I did copy many weeks ago, I kept a copy of my directory numbers. I copied from the internal nand, just the rootfs while running from the nand, to an external sdcard in the sdcard slot. Here is the before after numbers, which are very close, the small size difference in my case is because of the larger directory space of my 2GB sdcard. I was USING EXT2 FILE SYSTEM.
Before the copy
>mkfs -t ext2 /dev/mmcblk0p1
>mkdir /mnt/sdcard
>mount /dev/mmcblk0p1 /mnt/sdcard
>df
Filesystem 1K-blocks Used Available Use% Mounted on
rootfs 519168 151100 368068 30% /
tmpfs 257816 0 257816 0% /lib/init/rw
varrun 257816 36 257780 1% /var/run
varlock 257816 0 257816 0% /var/lock
udev 257816 12 257804 1% /dev
tmpfs 257816 0 257816 0% /dev/shm
tmpfs 257816 0 257816 0% /var/cache/apt
/dev/mmcblk0p1 1965176 2928 1862420 1% /mnt/sdcard
After copy:
>cp -ax / /mnt/sdcard # takes 13 minutes
>cp -a /dev /mnt/sdcard
>df
Filesystem 1K-blocks Used Available Use% Mounted on
rootfs 519168 151100 368068 30% /
tmpfs 257816 0 257816 0% /lib/init/rw
varrun 257816 36 257780 1% /var/run
varlock 257816 0 257816 0% /var/lock
udev 257816 12 257804 1% /dev
tmpfs 257816 0 257816 0% /dev/shm
tmpfs 257816 0 257816 0% /var/cache/apt
/dev/mmcblk0p1 1965176 300072 1565276 17% /mnt/sdcard
Does this not look different from what you got? Were you using ext3 ??