Which I can see now may be 8 (1024 byte) blocks too many.
A little bit of hex dumping the starting 512 bytes of the images and comparing them should tell the story.
If too many, I would expect the "hidden 1" to be a duplicate of those blocks at the start of the mmcblk0p1 image.
An easy thing to check for before we turn those loose on the world.
I.E: When I wrote that the total was 8 (1024 byte) blocks too short, I hadn't accounted for the FAT32 MBR&Partiton area of (16 512 byte, 8 1024 byte) blocks which does not show up in the /cat/partitions output.
Ah, well, better too much than too little.
Last edited by knc1; 09-26-2012 at 02:26 PM.