Wow, I was able to get the Chumby to work on a 4GB micro-SD chip. I took the 1GB micro-SD out of the Chumby and with the instructions from http://www.linuxtoys.org/chumbot/chumby_as_robot.pdf, I was able to get the 4GB micro-SD to work with the Chumby. The pdf file was notes from a lecture at the Home Brew Robotics Club that was given by Bob Smith. This is a pretty amazing set of notes. You can find pointers to the notes at http://www.demandperipherals.com. There is a second set of notes which describes the interface elements fro a robot which is based on Demand Peripherals BaseBoard4 set. In looking at the way in which the BaseBoard4 works, I am seriously considering using one of their boards to control other elements of these robots that I am thinking of building.
Essentially what I did was take the 1GB micro-SD out of the Chumby, by removing the 4 screws from the back, pulling the back away from the case, pulling the bottom panel off and away from the Chumby, and opening up the micro-SD cage cover. I then performed a "dd if=/dev/sde of=Chumby_Disk.img" to get an image of the micro-SD onto my Ubuntu laptop. I then setup the 4GB micro-SD with the same set of partitions: 3 150MB partitions and one extended partition (with a 128MB partition and a 3+GB partition with the remaining space). The only difference was that last partition space of over 3GB. I then performed a "dd if=Chumby_Disk.img of=/dev/sde" to get the image onto the 4GB micro-SD. When you boot up the Chumby, you must wait for the Chumby to finish doing its check of the micro-SD which in this case is much bigger. I can now breath a little more knowing that I can get back to the original micro-SD in a different size. I then put the original 1GB micro-SD in a safe place.
So how come you cannot buy a 1GB micro-SD any more? I wasn't able to find one anywhere. The smallest size that I was able to find was 2GB. I am of course happy with the fact that I have a 4GB micro-SD in the Chumby to play around with. More on this later.
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