Tips:
Partition Tips
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With BIGDOS all partitons must be >32 MB

For TOS 1.04 and 2.06:
Boot partition cluster size must be between 2KB and 16KB.
So max. size for BOOT PARTITION is 1GB
Other partitions can be up to 2GB using 32KB clusters.


For KAOS 1.4.2:
Boot partition cluster size must be between 2KB and 32KB.
All partitions, including BOOT PARTITION, can have 2GB using 32KB clusters.

I checked this with my KINGSTON card and a 40GB 2.5" HDD with same results.
Acronis partitioning program selects always the smallest cluster size
(depending on partition size). This was in case of my 128 MB card 1KB

OK now we know that this is a limitation of TOS 1.04 and 2.06.