Thank you for the info -- you've saved me another day of searching! Defragging wouldn't matter if I could just definitively prove that Linux was doing correctly and the RTOS' implementation was bad, then I could submit a request for WindRiver to fix it. I highly doubt Linux is at fault here as I've never had a problem using vfat disks back and forth from Windows. Either way, that's a whole lot of time that I don't have.
I'll try to incorporate the script you linked to. The comment at the top of the script doesn't exactly give me a warm-fuzzy:
Quote:
# Are you really crazy enough to be using this? It might blow your data
# into tiny little useless chunks.
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Wow! :-)