Finally getting a chance to work on this again (this is a project at work, so its get time when I have time to spare
Flashed the slightly reduced images onto my "2GB" cards...
About to overwrite the contents of disk 2 with new data. Proceed? (y/n) y
2001194496/2001194496 bytes written in total
Boot fine as well. Thanks for taking the feedback and working with it, it is appreciated.