Hi everone
not sure where this topic went but I had the same issue updating my columbus unit in my vrs and here is what I worked out:
1. you cannot just remove some of the country files from some other country to reduce the file size to fit the SD card as there is a checksum that causes an error. You could possibly re-engineer this but that's questionable.
2. Not all 32G SDcards are created equal, I was using Toshiba 90mb/s but it formatted to 28.5G and the files would not fit on either fat32, exFat or NTFS. I then looked at my sandisk 80mb/s 32G card and it formats to 29.7G and the the files fitted ok.
I guess the answer is that if you are not sure just get a 64G card and the problem will go away or go through all your 32G cards until you find one that formats to 29.5G which is what I did.
cheers
Chris
AUS