Not allowed to fill filesystem to 100%???
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We have created some 300 GB lvm2 (RH 4.0 AS) filesystems for our PostgreSQL databases. However, we tried to copy one of the larger filesystems over to the new lvm filesystem and the copy abended due to being. The system was reporting that the file system was 100% full with 0 blocks free. However, a df reported almost 16GB free.
If it's an ext2/3 filesystem, the default reserved space is 5%. Check the man pages for mke2fs and tune2fs.
Also, you might have run out of inodes, try "df -i", though that only happens with lots of little files and databases tend to be the opposite.
HTH