Success!
I finally got the entire library on the external SD card of my old Android Gingerbread device.
Things I learned:
1. because of the FAT32 file system limitations, I changed the Smartdevice Plugin Save template to {id}. This minimized the FAT entries required for each book.
2. CC and or Calibre can get confused in metadata db processing (on this device anyway) unless I stop and restart each program after every few hundred books.
3. Never try to send more than about 1000 books at a time. It always ended in error and disconnect.
ymmv
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