[syslinux] [Sugar-devel] Unbootable machine

[Mitch Bradley]

 http://advancemame.sourceforge.net/doc-makebootfat.html#7 suggests that 
the USB-ZIP option forces a geometry with 32 sectors and 64 heads.  That 
makes the cylinder size strongly aligned.  To the extent that this and 
other tools follow the convention of aligning partitions on cylinder 
boundaries, it's a start toward making things easy for the wear leveling 
software.

As has been mentioned, other things need to be aligned too, so 
makebootfat might not be a complete solution, but it isn't "guaranteed 
broken right out of the box".