Well, I tried to render luxembourg using the osm.pbf file from geofabrik, without splitting it, and than the map is good. As soon as I split it (also if the output is only one single osm.pbf tile),
I have missing portions in the map.

I use the following commands for splitting (newest splitter):
java -Xms4000m -Xmx6800m -jar splitter.jar --max-nodes=1250000 --output=pbf --overlap=5000  --geonames-file=cities15000 --description=luxembourg --mapid=64230000 luxembourg.osm.pbf


And this is the splitter output:
cache=
description=luxembourg
geonames-file=cities15000
legacy-mode=false
mapid=64230000
max-areas=255
max-nodes=1250000
max-threads=8 (auto)
mixed=false
no-trim=false
output=pbf
output-dir=
overlap=5000
resolution=13
split-file=
status-freq=120
write-kml=
Elapsed time: 0s   Memory: Current 3833MB (20MB used, 3813MB free) Max 6044MB
Time started: Wed Oct 17 13:18:08 CEST 2012
Map is being split for resolution 13:
 - area boundaries are aligned to 0x800 map units
 - areas are multiples of 0x1000 map units wide and high
Processing c:\openmtbmap\osmpbf_geofabrik\luxembourg.osm.pbf
Bounding box 5.733033000000001 49.445530000000005 6.532249 50.184960000000004
in 1 file
Time: Wed Oct 17 13:18:09 CEST 2012
Exact map coverage is (49.44551467895508,5.733017921447754) to (50.184946060180664,6.532230377197266)
Trimmed and rounded map coverage is (49.482421875,5.712890625) to (50.185546875,6.50390625)
Splitting nodes into areas containing a maximum of 1'250'000 nodes each...
Area (49.482421875,5.712890625) to (50.185546875,6.50390625) contains 997'119 nodes. DONE!
1 areas:
Area 64230000 covers (0x233000,0x41000) to (0x23b000,0x4a000) LU-Luxembourg
Writing out split osm files Wed Oct 17 13:18:09 CEST 2012
Processing 1 areas in a single pass
(49.482421875,5.712890625) to (50.185546875,6.50390625)
Starting pass 1 of 1, processing 1 areas (64230000 to 64230000)
Grid [512][512] for grid area (49.3751335144043,5.605602264404297) to (50.2928352355957,6.611194610595703) requires max. 1 checks for each no
Grid was created in 62 ms
Allocating three-tier structure to save area info (HashMap->vector->chunkvector)
Allocating three-tier structure to save area info (HashMap->vector->chunkvector)
Processing c:\openmtbmap\osmpbf_geofabrik\luxembourg.osm.pbf
Bounding box 5.733033000000001 49.445530000000005 6.532249 50.184960000000004
MAP occupancy: 1'000'000, number of area dictionary entries: 1 of 65535
Map details: HashMap -> 7 vectors for 88'816 chunks(vector usage < 1%)
Writing ways Wed Oct 17 13:18:11 CEST 2012
Writing relations Wed Oct 17 13:18:13 CEST 2012
***********************************************************
Final statistics
***********************************************************
Needed dictionary entries: 1 of 65535
coords occupancy
MAP occupancy: 1'036'326
Length-6 chunks: 91'338 (Bytes: 2'192'112)
Length-10 chunks: 0 (Bytes: 0)
Length-14 chunks: 0 (Bytes: 0)
Length-18 chunks: 0 (Bytes: 0)
Length-22 chunks: 0 (Bytes: 0)
Length-26 chunks: 0 (Bytes: 0)
Length-30 chunks: 0 (Bytes: 0)
Length-34 chunks: 0 (Bytes: 0)
Length-38 chunks: 0 (Bytes: 0)
Length-42 chunks: 0 (Bytes: 0)
Length-46 chunks: 0 (Bytes: 0)
Length-50 chunks: 0 (Bytes: 0)
Length-54 chunks: 0 (Bytes: 0)
Length-58 chunks: 0 (Bytes: 0)
Length-62 chunks: 0 (Bytes: 0)
Length-66 chunks: 0 (Bytes: 0)
Length-68 chunks: 0 (Bytes: 0)
RLE compresion info: compressed / uncompressed size / ratio: 548'028 / 1'526'290 / 65%
Map details: HashMap -> 8 vectors for 91'338 chunks(vector usage < 1%)
ways occupancy
MAP occupancy: 103'579
Length-6 chunks: 29'433 (Bytes: 706'392)
Length-10 chunks: 0 (Bytes: 0)
Length-14 chunks: 0 (Bytes: 0)
Length-18 chunks: 0 (Bytes: 0)
Length-22 chunks: 0 (Bytes: 0)
Length-26 chunks: 0 (Bytes: 0)
Length-30 chunks: 0 (Bytes: 0)
Length-34 chunks: 0 (Bytes: 0)
Length-38 chunks: 0 (Bytes: 0)
Length-42 chunks: 0 (Bytes: 0)
Length-46 chunks: 0 (Bytes: 0)
Length-50 chunks: 0 (Bytes: 0)
Length-54 chunks: 0 (Bytes: 0)
Length-58 chunks: 0 (Bytes: 0)
Length-62 chunks: 0 (Bytes: 0)
Length-66 chunks: 0 (Bytes: 0)
Length-68 chunks: 0 (Bytes: 0)
RLE compresion info: compressed / uncompressed size / ratio: 176'598 / 254'588 / 31%
Map details: HashMap -> 1 vectors for 29'433 chunks(vector usage < 2%)

Thread worker-3 has finished
Thread worker-2 has finished
Thread worker-5 has finished
Thread worker-4 has finished
Thread worker-6 has finished
Thread worker-0 has finished
Thread worker-1 has finished
Time finished: Wed Oct 17 13:18:13 CEST 2012
Total time taken: 5s

On 17.10.2012 12:54, Felix Hartmann wrote:
See the following screenshots - map vs josm - look at the highway junction both times on the top as a reference. There is about 1km missing - I really cannot understand how and why this happens.. (and not there is no related error message or missing tile), in the east of luxembourg, mkgmap also cuts away a bit.:



-- 
keep on biking and discovering new trails

Felix
openmtbmap.org & www.velomap.org

-- 
keep on biking and discovering new trails

Felix
openmtbmap.org & www.velomap.org