[mk01]

My guess is VFAT didn't survive the dd-ing into img file. There is no magic while doing the clone - first partition (32mb) is copied with dd. If PCs would have been 100% reliable then it MUST boot. Apparently no so I will re-code this to proper mkfs.vfat and copy files (with -v).

Also initramfs should be uncommented as after reflash we need resize + swap creation. Will fix.

Size difference is ok as xbianclone is not doing block copy. It uses btrfs internal functions. And always makes .img as small as possible (to be able to restore to smaller SDs as well in case of emergency).