Could you try with the attached patch and (if it is still NOT OK) please send me the whole output and the exact size of the mdr file.
Sorry, the complete europe map still seems to trigger some limits. It's again the mdr.img being >240MB. I uploaded the faulty file to the mkgmap website. Here is the debug output ... C:\Users\peter\Desktop\aio\europa-tiles>java -enableassertions -Xmx4000M -jar "C:\Program Files\openstreetmap.org\mkgmap\mkgmap-fix2.jar" --verbose --max-jobs --latin1 --code-page=1252 --description=" OSM AiO Europe 20110407" --country-name="Europe-country"' --country-abbr="EU-c" --region-name="Europe-region" --region-abbr="EU-r" --area-name=EU --series-name="OSM AiO Europe" --family-name=OSM --fam ily-id=6324 --product-id=1 --draw-priority=10 --nsis --tdbfile --index --route --net 70014*.img file size 0 file size 0 write size values block size=512 shc=4,16,32, end=67 file size 0 write size values block size=512 shc=4,16,32, end=67 write size values block size=4096 shc=4,16,32, end=499360 shc=4,16,64, end=499360 shc=4,16,128, end=499360 shc=4,16,256, end=499360 shc=4,16,512, end=499360 shc=4,16,1024, end=499360 shc=8,16,32, end=499360 shc=8,16,64, end=499360 shc=8,16,128, end=499360 shc=8,16,256, end=499360 shc=8,16,512, end=499360 shc=8,16,1024, end=499360 shc=16,16,32, end=499360 shc=16,16,64, end=499360 shc=16,16,128, end=499360 shc=16,16,256, end=499360 shc=16,16,512, end=499360 shc=16,16,1024, end=499360 shc=32,16,32, end=499360 shc=32,16,64, end=499360 shc=32,16,128, end=499360 shc=32,16,256, end=499360 shc=32,16,512, end=499360 shc=32,16,1024, end=499360 One more thought: the limit of 240 MB looks like the least siginifcant 4 bits of some limiting variable are masked out somehow, 256 - 16 = 240!? Another thoght: Before r1919 the Europe map was working for me. What did change with r1919 or later? Is there a tool for download to analyse the imgfmt-structure? Peter