Hi there, I tried to install KaOS for servel months (well, at least I tried a few times but 'till now had not the time to look deeper in it)

OK:

I tried KaOS 2016.07 and since I wanted a special btrfs layout I thought that was the reason, so I tried again with different settings. 20% and than rsync fail. (And It always took a while.)

Next I tired version 2016.09. Same behaviour.
So I hade a look at the error codes of rsync switched to another USB stick but that didn't help.

The next I read was something about an extend partition bug:

on shell while the rsync was running:
-> "ps axww | grep rsync" -> rsync was running
-> "mount | grep sda" -> only /dev/sda2 was mounted on /tmp/calamares-xxyyzz/boot
-> sda2 was NOT mounted anywhere and therefor not mouted at /tmp/calamares-xxyyzz (sda2 intended as /)
-> rsync fails with error 11 when the tmpfs /tmp (/tmp/calamares-xxyyzz) runs full
-> this is reproduceable
I tried to mount it before running calamares but calamares just uses an other mountpoint (/tmp/calamares-uuvvww)
-> tried to figure out how to circumvant calamares in this, no luck till now

Data:

fdisk -l 
/dev/sda1  *        2048   1955839   1953792   954M 83 Linux
/dev/sda2        1955840  64456703  62500864  29,8G 83 Linux
/dev/sda3       64456704 468860927 404404224 192,9G  f W95 Erw. (LBA)
/dev/sda5       64458752  71811071   7352320   3,5G 82 Linux Swap / Solaris
/dev/sda6       71813120 468860927 397047808 189,3G 83 Linux

df /tmp/calamares-root-11smlcnj/
Dateisystem    Größe Benutzt Verf. Verw% Eingehängt auf
tmpfs           3,8G    3,8G     0  100% /tmp

mount | grep tmpfs
dev on /dev type devtmpfs (rw,nosuid,relatime,size=3876108k,nr_inodes=969027,mode=755)
run on /run type tmpfs (rw,nosuid,nodev,relatime,mode=755)
tmpfs on /dev/shm type tmpfs (rw,nosuid,nodev)
tmpfs on /sys/fs/cgroup type tmpfs (ro,nosuid,nodev,noexec,mode=755)
tmpfs on /tmp type tmpfs (rw,nosuid,nodev,relatime)
tmpfs on /run/user/1000 type tmpfs (rw,nosuid,nodev,relatime,size=777116k,mode=700,uid=1000,gid=100)
dev on /tmp/calamares-root-w10a9dzh/dev type devtmpfs (rw,nosuid,relatime,size=3876108k,nr_inodes=969027,mode=755)
tmpfs on /tmp/calamares-root-w10a9dzh/run type tmpfs (rw,relatime)
tmpfs on /tmp type tmpfs (rw,nosuid,nodev,relatime)
[root@localhost ~]# mount | grep sda
/dev/sda1 on /tmp/calamares-root-w10a9dzh/boot type ext4 (rw,relatime,data=ordered)

installation.log

[...]
08:07:11 [1]: ViewModule loading self for instance "partition@partition" 
ViewModule at address 0x1766c20 
Calamares::PluginFactory at address PartitionViewStepFactory(0x39acc20)
ViewStep at address PartitionViewStep(0x39aaa40) 
08:07:11 [1]: WARNING: bad default filesystem configuration for partition module. Reverting to ext4 as default. 
[...]
08:07:17 [1]: LIST OF DETECTED DEVICES:
node    capacity        name    prettyName 
08:07:17 [1]: "/dev/sda" 240054796800 "ATA SanDisk SDSSDA24" "ATA SanDisk SDSSDA24 – 223,57 GiB (/dev/sda)" 
08:07:21 [1]: "Osprober lines, clean:\n" 
08:07:21 [1]: Updating partitioning state widgets. 
08:07:21 [0]: QCoreApplication::postEvent: Unexpected null receiver
08:07:21 [1]: Creating immutable copy for node: "/dev/sda" 
08:07:21 [0]: QFileInfo::absolutePath: Constructed with empty filename
08:07:21 [0]: QFileInfo::absolutePath: Constructed with empty filename
08:07:21 [0]: QFileInfo::absolutePath: Constructed with empty filename
08:07:21 [1]: Required  storage B: 10200547328 "(9GB)" 
08:07:21 [1]: Available storage B: 932315136 "(0GB)" 
08:07:21 [1]: Required  storage B: 10200547328 "(9GB)" 
08:07:21 [1]: Available storage B: 31718309888 "(29GB)"
08:07:21 [1]: Partition "/dev/sda2" authorized for resize + autopartition install. 
08:07:21 [1]: Required  storage B: 8053063680 "(7GB)" 
08:07:21 [1]: Available storage B: 1000341504 "(0GB)" 
08:07:21 [1]: Required  storage B: 8053063680 "(7GB)" 
08:07:21 [1]: Available storage B: 32000442368 "(29GB)" 
08:07:21 [1]: Partition "/dev/sda2" authorized for replace install. 
08:07:21 [1]: Updating partitioning preview widgets. 
08:07:21 [0]: QCoreApplication::postEvent: Unexpected null receiver
08:07:27 [1]: Updating partitioning preview widgets. 
08:07:27 [0]: QCoreApplication::postEvent: Unexpected null receiver
08:07:30 [1]: Choice applied:  4 
08:07:40 [1]: old boundaries: 2048 1955839 1953792 
08:07:40 [1]: new boundaries: 2048 1955839 
08:07:40 [1]: dirty status: false 
08:07:49 [1]: old boundaries: 1955840 64456703 62500864 
08:07:49 [1]: new boundaries: 1955840 64456703 
08:07:49 [1]: dirty status: false 
08:08:20 [0]: QLayout: Attempting to add QLayout "" to QWidget "", which already has a layout
08:08:20 [0]: QLayout: Attempting to add QLayout "" to QWidget "", which already has a layout
08:08:20 [0]: QFileInfo::absolutePath: Constructed with empty filename
08:08:20 [0]: QFileInfo::absolutePath: Constructed with empty filename
08:08:20 [0]: QFileInfo::absolutePath: Constructed with empty filename
08:08:20 [1]: PartitionCodeModule has been asked for jobs. About to return: "Löse alle temporär eingehängten Partitionen.\nKläre eingehängte Partitionen für Operationen auf /dev/sda\nSetze Partitionsinformationen" 
08:08:20 [1]: Gathering UUIDs for partitions that exist now. 
08:08:20 [1]: QHash(("/dev/sda1", "b9683eab-73f6-419e-ba97-4f74f6aeea87")("/dev/sda2", "a208a7fe-42d3-4f71-b750-b8cb3e9b489b")("/dev/sda3", "")("/dev/sda5", "46057bc0-fc97-4795-8efe-dffefdb87ab6")("/dev/sda6", "816ad2d7-ac91-4bdf-b1c7-55151a738edc")) 
08:08:20 [1]: Writing to GlobalStorage["partitions"] 
08:08:20 [1]: "/dev/sda1" mtpoint: "/boot" fs: "ext4" "b9683eab-73f6-419e-ba97-4f74f6aeea87" 
08:08:20 [1]: "/dev/sda2" mtpoint: "/" fs: "Btrfs" "a208a7fe-42d3-4f71-b750-b8cb3e9b489b" 
08:08:20 [1]: "/dev/sda3" mtpoint: "" fs: "erweitert" "" 
08:08:20 [1]: "/dev/sda5" mtpoint: "" fs: "Linux-Swap" "46057bc0-fc97-4795-8efe-dffefdb87ab6" 
08:08:20 [1]: "/dev/sda6" mtpoint: "" fs: "Btrfs" "816ad2d7-ac91-4bdf-b1c7-55151a738edc" 
08:08:20 [8]: QVariant(QString, "b9683eab-73f6-419e-ba97-4f74f6aeea87") "/dev/sda1" "/boot" "ext4"
08:08:20 [8]: QVariant(QString, "a208a7fe-42d3-4f71-b750-b8cb3e9b489b") "/dev/sda2" "/" "Btrfs"
08:08:20 [8]: QVariant(QString, "") "/dev/sda3" "" "erweitert"
08:08:20 [8]: QVariant(QString, "46057bc0-fc97-4795-8efe-dffefdb87ab6") "/dev/sda5" "" "Linux-Swap"
08:08:20 [8]: QVariant(QString, "816ad2d7-ac91-4bdf-b1c7-55151a738edc") "/dev/sda6" "" "Btrfs"
08:08:20 [1]: Gathering UUIDs for partitions that exist now.
08:08:20 [1]: QHash(("/dev/sda1", "b9683eab-73f6-419e-ba97-4f74f6aeea87")("/dev/sda2", "a208a7fe-42d3-4f71-b750-b8cb3e9b489b")("/dev/sda3", "")("/dev/sda5", "46057bc0-fc97-4795-8efe-dffefdb87ab6")("/dev/sda6", "816ad2d7-ac91-4bdf-b1c7-55151a738edc")) 
08:08:20 [1]: Writing to GlobalStorage["partitions"] 
08:08:20 [1]: "/dev/sda1" mtpoint: "/boot" fs: "ext4" "b9683eab-73f6-419e-ba97-4f74f6aeea87" 
08:08:20 [1]: "/dev/sda2" mtpoint: "/" fs: "Btrfs" "a208a7fe-42d3-4f71-b750-b8cb3e9b489b" 
08:08:20 [1]: "/dev/sda3" mtpoint: "" fs: "erweitert" "" 
08:08:20 [1]: "/dev/sda5" mtpoint: "" fs: "Linux-Swap" "46057bc0-fc97-4795-8efe-dffefdb87ab6" 
08:08:20 [1]: "/dev/sda6" mtpoint: "" fs: "Btrfs" "816ad2d7-ac91-4bdf-b1c7-55151a738edc" 
08:08:20 [8]: QVariant(QString, "b9683eab-73f6-419e-ba97-4f74f6aeea87") "/dev/sda1" "/boot" "ext4"
08:08:20 [8]: QVariant(QString, "a208a7fe-42d3-4f71-b750-b8cb3e9b489b") "/dev/sda2" "/" "Btrfs"
08:08:20 [8]: QVariant(QString, "") "/dev/sda3" "" "erweitert"
08:08:20 [8]: QVariant(QString, "46057bc0-fc97-4795-8efe-dffefdb87ab6") "/dev/sda5" "" "Linux-Swap"
08:08:20 [8]: QVariant(QString, "816ad2d7-ac91-4bdf-b1c7-55151a738edc") "/dev/sda6" "" "Btrfs"
08:08:30 [1]: loading ok  
08:08:32 [1]: PartitionCodeModule has been asked for jobs. About to return: "Löse alle temporär eingehängten Partitionen.\nKläre eingehängte Partitionen für Operationen auf /dev/sda\nSetze Partitionsinformationen" 
08:08:32 [0]: Starting job "Löse alle temporär eingehängten Partitionen." 
[...]
08:08:32 [1]: "/dev/sda2 /tmp/calamares-root-11smlcnj btrfs rw,relatime,ssd,space_cache,subvolid=5,subvol=/ 0 0" 
08:08:32 [1]: INSERTING pair (device, mountPoint) "/dev/sda2" "/tmp/calamares-root-11smlcnj" 
08:08:32 [1]: "/dev/sda1 /tmp/calamares-root-11smlcnj/boot ext4 rw,relatime,data=ordered 0 0" 
08:08:32 [1]: INSERTING pair (device, mountPoint) "/dev/sda1" "/tmp/calamares-root-11smlcnj/boot" 
08:08:32 [1]: Will try to umount path "/tmp/calamares-root-11smlcnj" 
08:08:32 [1]: Will try to umount path "/tmp/calamares-root-11smlcnj/boot" 
08:08:32 [1]: ClearTempMountsJob finished. Here's what was done:
 "Successfully unmounted /tmp/calamares-root-11smlcnj." 
08:08:32 [0]: Starting job "Kläre eingehängte Partitionen für Operationen auf /dev/sda" 
08:08:33 [1]: ClearMountsJob finished. Here's what was done:
 "Successfully cleared swap /dev/sda5." 
08:08:33 [0]: Starting job "Setze Partitionsinformationen" 
08:08:33 [1]: Gathering UUIDs for partitions that exist now. 
08:08:33 [1]: QHash(("/dev/sda1", "b9683eab-73f6-419e-ba97-4f74f6aeea87")("/dev/sda2", "a208a7fe-42d3-4f71-b750-b8cb3e9b489b")("/dev/sda3", "")("/dev/sda5", "46057bc0-fc97-4795-8efe-dffefdb87ab6")("/dev/sda6", "816ad2d7-ac91-4bdf-b1c7-55151a738edc")) 
08:08:33 [1]: Writing to GlobalStorage["partitions"]
08:08:33 [1]: Writing to GlobalStorage["partitions"] 
08:08:33 [1]: "/dev/sda1" mtpoint: "/boot" fs: "ext4" "b9683eab-73f6-419e-ba97-4f74f6aeea87" 
08:08:33 [1]: "/dev/sda2" mtpoint: "/" fs: "Btrfs" "a208a7fe-42d3-4f71-b750-b8cb3e9b489b" 
08:08:33 [1]: "/dev/sda3" mtpoint: "" fs: "erweitert" "" 
08:08:33 [1]: "/dev/sda5" mtpoint: "" fs: "Linux-Swap" "46057bc0-fc97-4795-8efe-dffefdb87ab6" 
08:08:33 [1]: "/dev/sda6" mtpoint: "" fs: "Btrfs" "816ad2d7-ac91-4bdf-b1c7-55151a738edc" 
08:08:33 [0]: Starting job "mount" 
08:08:34 [0]: Starting job "unpackfs" 
08:08:37 [0]: Installation failed: 
08:08:37 [0]: - message: "Failed to unpack image /bootmnt/kdeos/x86_64/root-image.sqfs" 
08:08:37 [0]: - details: "rsync failed with error code 11."
[...]

So far,
Mia