[Nexus One Android Development] Chahk:
I really want to help you get this working. It seems a shame to let perfectly good 95MB go to waste. Running the backup now, will post the results shortly.

a2sd sysinfo after running a2sd cachepart:

[ ] Apps2SD is launching...
__ _____
| \ |
| | |
|__/ | Darktremor Apps2SD 2.7.5.2 (2010-09-30)

[ ] GetProp Command = /system/bin/toolbox getprop
[ ] SetProp Command = /system/bin/toolbox setprop
[ ] Mount Point = /sd-ext
[ ] Starting Darktremor Apps2SD Version 2.7.5.2
[ ] Launching Apps2SD Start Program with sysinfo
[ ] Starting Darktremor Apps2SD in sysinfo mode
[ ] System Information:
[ ] Kernel Information:
Linux version 2.6.35.6-cyanogenmod (chrissoyars@fembot) (gcc version 4.4.0 (GCC) ) #204 PREEMPT Tue Oct 5 00:07:33 UTC 2010
[ ] CPU Information:
Processor : ARMv7 Processor rev 2 (v7l)
BogoMIPS : 560.49
Features : swp half thumb fastmult vfp edsp thumbee neon
CPU implementer : 0x51
CPU architecture: 7
CPU variant : 0x0
CPU part : 0x00f
CPU revision : 2

Hardware : mahimahi
Revision : 0081
Serial : 0000000000000000
[ ] Memory:
/system/bin/starta2sd: line 366: i: command not found
MemTotal: 416188 kB
MemFree: 99652 kB
Buffers: 12964 kB
Cached: 152428 kB
SwapCached: 0 kB
Active: 191608 kB
Inactive: 98860 kB
Active(anon): 125132 kB
Inactive(anon): 304 kB
Active(file): 66476 kB
Inactive(file): 98556 kB
Unevictable: 0 kB
Mlocked: 0 kB
SwapTotal: 0 kB
SwapFree: 0 kB
Dirty: 0 kB
Writeback: 0 kB
AnonPages: 125084 kB
Mapped: 53188 kB
Shmem: 360 kB
Slab: 10984 kB
SReclaimable: 5020 kB
SUnreclaim: 5964 kB
KernelStack: 3048 kB
PageTables: 9632 kB
NFS_Unstable: 0 kB
Bounce: 0 kB
WritebackTmp: 0 kB
CommitLimit: 208092 kB
Committed_AS: 2864064 kB
VmallocTotal: 466944 kB
VmallocUsed: 119620 kB
VmallocChunk: 314372 kB
[ ] Mounted Partition:
rootfs / rootfs ro,relatime 0 0
tmpfs /dev tmpfs rw,relatime,mode=755 0 0
devpts /dev/pts devpts rw,relatime,mode=600 0 0
proc /proc proc rw,relatime 0 0
sysfs /sys sysfs rw,relatime 0 0
none /acct cgroup rw,relatime,cpuacct 0 0
tmpfs /mnt/asec tmpfs rw,relatime,mode=755,gid=1000 0 0
none /dev/cpuctl cgroup rw,relatime,cpu 0 0
/dev/block/mtdblock3 /system yaffs2 ro,relatime 0 0
/dev/block/mtdblock5 /data yaffs2 rw,nosuid,nodev,relatime 0 0
/dev/block/mtdblock4 /cache yaffs2 rw,nosuid,nodev,relatime 0 0
/dev/block/mtdblock4 /data/dalvik-cache yaffs2 rw,nosuid,nodev,relatime 0 0
/dev/block/mmcblk0p2 /sd-ext ext2 rw,noatime,nodiratime,barrier=1,data=ordered 0 0
/sys/kernel/debug /sys/kernel/debug debugfs rw,relatime 0 0
/dev/block/vold/179:1 /mnt/sdcard vfat rw,dirsync,nosuid,nodev,noexec,relatime,uid=1000,gid=1015,fmask=0702,dmask=0702,allow_utime=0020,codepage=cp437,iocharset=iso8859-1,shortname=mixed,utf8,errors=remount-ro 0 0
/dev/block/vold/179:1 /mnt/secure/asec vfat rw,dirsync,nosuid,nodev,noexec,relatime,uid=1000,gid=1015,fmask=0702,dmask=0702,allow_utime=0020,codepage=cp437,iocharset=iso8859-1,shortname=mixed,utf8,errors=remount-ro 0 0
tmpfs /mnt/sdcard/.android_secure tmpfs ro,relatime,size=0k,mode=000 0 0
[ ] Valid Partitions:
nodev sysfs
nodev rootfs
nodev bdev
nodev proc
nodev cgroup
nodev tmpfs
nodev debugfs
nodev sockfs
nodev pipefs
nodev anon_inodefs
nodev devpts
ext2
ext3
ext4
nodev ramfs
vfat
yaffs
yaffs2
nodev mtd_inodefs
[ ] Swap Information:
: applet not found
cat: can't open '/proc/swaps': No such file or directory
cat: can't open '/proc/swaps': No such file or directory
[ ] Partition Information:
Filesystem Size Used Available Use% Mounted on
tmpfs 203.2M 0 203.2M 0% /dev
tmpfs 203.2M 0 203.2M 0% /mnt/asec
/dev/block/mtdblock3 145.0M 113.8M 31.2M 78% /system
/dev/block/mtdblock5 196.3M 74.4M 121.8M 38% /data
/dev/block/mtdblock4 95.0M 76.1M 18.9M 80% /cache
/dev/block/mtdblock4 95.0M 76.1M 18.9M 80% /data/dalvik-cache
/dev/block/mmcblk0p2 457.4M 114.5M 318.4M 26% /sd-ext
/dev/block/vold/179:1
14.4G 7.6G 6.8G 53% /mnt/sdcard
/dev/block/vold/179:1
14.4G 7.6G 6.8G 53% /mnt/secure/asec
[ ] MTD Information:
dev: size erasesize name
mtd0: 000e0000 00020000 "misc"
mtd1: 00500000 00020000 "recovery"
mtd2: 00280000 00020000 "boot"
mtd3: 09100000 00020000 "system"
mtd4: 05f00000 00020000 "cache"
mtd5: 0c440000 00020000 "userdata"
[ ] Phone Serial #: HT035P901113
[ ] Bootloader Version: 0.33.0012
[ ] Radio Baseband: 5.08.00.04
[ ] Hardware ID: mahimahi
[ ] Product Model: Nexus One
[ ] Product Brand: passion
[ ] Product Device: passion
[ ] Product Board: mahimahi
[ ] Rom: passion-user 2.2.1 FRG83 60505 release-keys
[ ] Base Rom Version:
[ ] Setting File System Ready property to 1.

Wow, this seems to have fixed it. The phone reports ~120MB free, and df says 38% usage on /data.

a2sd sysinfo after running a2sd nocache:

[ ] Apps2SD is launching...
__ _____
| \ |
| | |
|__/ | Darktremor Apps2SD 2.7.5.2 (2010-09-30)

[ ] GetProp Command = /system/bin/toolbox getprop
[ ] SetProp Command = /system/bin/toolbox setprop
[ ] Mount Point = /sd-ext
[ ] Starting Darktremor Apps2SD Version 2.7.5.2
[ ] Launching Apps2SD Start Program with sysinfo
[ ] Starting Darktremor Apps2SD in sysinfo mode
[ ] System Information:
[ ] Kernel Information:
Linux version 2.6.35.6-cyanogenmod (chrissoyars@fembot) (gcc version 4.4.0 (GCC) ) #204 PREEMPT Tue Oct 5 00:07:33 UTC 2010
[ ] CPU Information:
Processor : ARMv7 Processor rev 2 (v7l)
BogoMIPS : 535.01
Features : swp half thumb fastmult vfp edsp thumbee neon
CPU implementer : 0x51
CPU architecture: 7
CPU variant : 0x0
CPU part : 0x00f
CPU revision : 2

Hardware : mahimahi
Revision : 0081
Serial : 0000000000000000
[ ] Memory:
/system/bin/starta2sd: line 366: i: command not found
MemTotal: 416188 kB
MemFree: 125088 kB
Buffers: 5088 kB
Cached: 149296 kB
SwapCached: 0 kB
Active: 167536 kB
Inactive: 98524 kB
Active(anon): 111716 kB
Inactive(anon): 472 kB
Active(file): 55820 kB
Inactive(file): 98052 kB
Unevictable: 0 kB
Mlocked: 0 kB
SwapTotal: 0 kB
SwapFree: 0 kB
Dirty: 0 kB
Writeback: 0 kB
AnonPages: 111684 kB
Mapped: 72316 kB
Shmem: 512 kB
Slab: 9848 kB
SReclaimable: 3852 kB
SUnreclaim: 5996 kB
KernelStack: 2968 kB
PageTables: 9888 kB
NFS_Unstable: 0 kB
Bounce: 0 kB
WritebackTmp: 0 kB
CommitLimit: 208092 kB
Committed_AS: 2900940 kB
VmallocTotal: 466944 kB
VmallocUsed: 119620 kB
VmallocChunk: 307204 kB
[ ] Mounted Partition:
rootfs / rootfs ro,relatime 0 0
tmpfs /dev tmpfs rw,relatime,mode=755 0 0
devpts /dev/pts devpts rw,relatime,mode=600 0 0
proc /proc proc rw,relatime 0 0
sysfs /sys sysfs rw,relatime 0 0
none /acct cgroup rw,relatime,cpuacct 0 0
tmpfs /mnt/asec tmpfs rw,relatime,mode=755,gid=1000 0 0
none /dev/cpuctl cgroup rw,relatime,cpu 0 0
/dev/block/mtdblock3 /system yaffs2 ro,relatime 0 0
/dev/block/mtdblock5 /data yaffs2 rw,nosuid,nodev,relatime 0 0
/dev/block/mtdblock4 /cache yaffs2 rw,nosuid,nodev,relatime 0 0
/dev/block/mmcblk0p2 /sd-ext ext2 rw,noatime,nodiratime,barrier=1,data=ordered 0 0
/sys/kernel/debug /sys/kernel/debug debugfs rw,relatime 0 0
/dev/block/vold/179:1 /mnt/sdcard vfat rw,dirsync,nosuid,nodev,noexec,relatime,uid=1000,gid=1015,fmask=0702,dmask=0702,allow_utime=0020,codepage=cp437,iocharset=iso8859-1,shortname=mixed,utf8,errors=remount-ro 0 0
/dev/block/vold/179:1 /mnt/secure/asec vfat rw,dirsync,nosuid,nodev,noexec,relatime,uid=1000,gid=1015,fmask=0702,dmask=0702,allow_utime=0020,codepage=cp437,iocharset=iso8859-1,shortname=mixed,utf8,errors=remount-ro 0 0
tmpfs /mnt/sdcard/.android_secure tmpfs ro,relatime,size=0k,mode=000 0 0
[ ] Valid Partitions:
nodev sysfs
nodev rootfs
nodev bdev
nodev proc
nodev cgroup
nodev tmpfs
nodev debugfs
nodev sockfs
nodev pipefs
nodev anon_inodefs
nodev devpts
ext2
ext3
ext4
nodev ramfs
vfat
yaffs
yaffs2
nodev mtd_inodefs
[ ] Swap Information:
: applet not found
cat: can't open '/proc/swaps': No such file or directory
cat: can't open '/proc/swaps': No such file or directory
[ ] Partition Information:
Filesystem Size Used Available Use% Mounted on
tmpfs 203.2M 0 203.2M 0% /dev
tmpfs 203.2M 0 203.2M 0% /mnt/asec
/dev/block/mtdblock3 145.0M 113.8M 31.2M 78% /system
/dev/block/mtdblock5 196.3M 148.8M 47.5M 76% /data
/dev/block/mtdblock4 95.0M 1.8M 93.2M 2% /cache
/dev/block/mmcblk0p2 457.4M 114.5M 318.4M 26% /sd-ext
/dev/block/vold/179:1
14.4G 7.6G 6.8G 53% /mnt/sdcard
/dev/block/vold/179:1
14.4G 7.6G 6.8G 53% /mnt/secure/asec
[ ] MTD Information:
dev: size erasesize name
mtd0: 000e0000 00020000 "misc"
mtd1: 00500000 00020000 "recovery"
mtd2: 00280000 00020000 "boot"
mtd3: 09100000 00020000 "system"
mtd4: 05f00000 00020000 "cache"
mtd5: 0c440000 00020000 "userdata"
[ ] Phone Serial #: HT035P901113
[ ] Bootloader Version: 0.33.0012
[ ] Radio Baseband: 5.08.00.04
[ ] Hardware ID: mahimahi
[ ] Product Model: Nexus One
[ ] Product Brand: passion
[ ] Product Device: passion
[ ] Product Board: mahimahi
[ ] Rom: passion-user 2.2.1 FRG83 60505 release-keys
[ ] Base Rom Version:
[ ] Setting File System Ready property to 1.

As expected, 76% used on /data when running cache off the internal storage.

a2sd sysinfo after running "a2sd cachepartreset" just to make sure:

[ ] Apps2SD is launching...
__ _____
| \ |
| | |
|__/ | Darktremor Apps2SD 2.7.5.2 (2010-09-30)

[ ] GetProp Command = /system/bin/toolbox getprop
[ ] SetProp Command = /system/bin/toolbox setprop
[ ] Mount Point = /sd-ext
[ ] Starting Darktremor Apps2SD Version 2.7.5.2
[ ] Launching Apps2SD Start Program with sysinfo
[ ] Starting Darktremor Apps2SD in sysinfo mode
[ ] System Information:
[ ] Kernel Information:
Linux version 2.6.35.6-cyanogenmod (chrissoyars@fembot) (gcc version 4.4.0 (GCC) ) #204 PREEMPT Tue Oct 5 00:07:33 UTC 2010
[ ] CPU Information:
Processor : ARMv7 Processor rev 2 (v7l)
BogoMIPS : 662.40
Features : swp half thumb fastmult vfp edsp thumbee neon
CPU implementer : 0x51
CPU architecture: 7
CPU variant : 0x0
CPU part : 0x00f
CPU revision : 2

Hardware : mahimahi
Revision : 0081
Serial : 0000000000000000
[ ] Memory:
/system/bin/starta2sd: line 366: i: command not found
MemTotal: 416188 kB
MemFree: 56520 kB
Buffers: 11636 kB
Cached: 211284 kB
SwapCached: 0 kB
Active: 233948 kB
Inactive: 103224 kB
Active(anon): 114288 kB
Inactive(anon): 252 kB
Active(file): 119660 kB
Inactive(file): 102972 kB
Unevictable: 0 kB
Mlocked: 0 kB
SwapTotal: 0 kB
SwapFree: 0 kB
Dirty: 0 kB
Writeback: 0 kB
AnonPages: 114260 kB
Mapped: 60840 kB
Shmem: 288 kB
Slab: 9928 kB
SReclaimable: 4276 kB
SUnreclaim: 5652 kB
KernelStack: 2472 kB
PageTables: 7640 kB
NFS_Unstable: 0 kB
Bounce: 0 kB
WritebackTmp: 0 kB
CommitLimit: 208092 kB
Committed_AS: 2196400 kB
VmallocTotal: 466944 kB
VmallocUsed: 113500 kB
VmallocChunk: 318468 kB
[ ] Mounted Partition:
rootfs / rootfs ro,relatime 0 0
tmpfs /dev tmpfs rw,relatime,mode=755 0 0
devpts /dev/pts devpts rw,relatime,mode=600 0 0
proc /proc proc rw,relatime 0 0
sysfs /sys sysfs rw,relatime 0 0
none /acct cgroup rw,relatime,cpuacct 0 0
tmpfs /mnt/asec tmpfs rw,relatime,mode=755,gid=1000 0 0
none /dev/cpuctl cgroup rw,relatime,cpu 0 0
/dev/block/mtdblock3 /system yaffs2 ro,relatime 0 0
/dev/block/mtdblock5 /data yaffs2 rw,nosuid,nodev,relatime 0 0
/dev/block/mtdblock4 /cache yaffs2 rw,nosuid,nodev,relatime 0 0
/dev/block/mtdblock4 /data/dalvik-cache yaffs2 rw,nosuid,nodev,relatime 0 0
/dev/block/mmcblk0p2 /sd-ext ext2 rw,noatime,nodiratime,barrier=1,data=ordered 0 0
/sys/kernel/debug /sys/kernel/debug debugfs rw,relatime 0 0
[ ] Valid Partitions:
nodev sysfs
nodev rootfs
nodev bdev
nodev proc
nodev cgroup
nodev tmpfs
nodev debugfs
nodev sockfs
nodev pipefs
nodev anon_inodefs
nodev devpts
ext2
ext3
ext4
nodev ramfs
vfat
yaffs
yaffs2
nodev mtd_inodefs
[ ] Swap Information:
: applet not found
cat: can't open '/proc/swaps': No such file or directory
cat: can't open '/proc/swaps': No such file or directory
[ ] Partition Information:
Filesystem Size Used Available Use% Mounted on
tmpfs 203.2M 0 203.2M 0% /dev
tmpfs 203.2M 0 203.2M 0% /mnt/asec
/dev/block/mtdblock3 145.0M 113.8M 31.2M 78% /system
/dev/block/mtdblock5 196.3M 148.8M 47.4M 76% /data
/dev/block/mtdblock4 95.0M 76.1M 18.9M 80% /cache
/dev/block/mtdblock4 95.0M 76.1M 18.9M 80% /data/dalvik-cache
/dev/block/mmcblk0p2 457.4M 114.5M 318.4M 26% /sd-ext
[ ] MTD Information:
dev: size erasesize name
mtd0: 000e0000 00020000 "misc"
mtd1: 00500000 00020000 "recovery"
mtd2: 00280000 00020000 "boot"
mtd3: 09100000 00020000 "system"
mtd4: 05f00000 00020000 "cache"
mtd5: 0c440000 00020000 "userdata"
[ ] Phone Serial #: HT035P901113
[ ] Bootloader Version: 0.33.0012
[ ] Radio Baseband: 5.08.00.04
[ ] Hardware ID: mahimahi
[ ] Product Model: Nexus One
[ ] Product Brand: passion
[ ] Product Device: passion
[ ] Product Board: mahimahi
[ ] Rom: passion-user 2.2.1 FRG83 60505 release-keys
[ ] Base Rom Version:
[ ] Setting File System Ready property to 1.

And it's back to 76% used on /data. This is really weird, as if it was writing the cache to both internal memory AND the /cache partition.