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The USBHostMSD interface will apparently only allow creation of 128 files on a flash disk. This is a problem because it prevents logging of very large amounts of data to a flash disk. In itself, the limit of 128 files should not be a big issue.
However the other part of the problem is that writing to individual files gets very slow once the file size gets large.
So it you max out the file size because of the speed problem, and then create a new file everything works great until you hit the 128 file limit.
Therefore it's not possible to come even close to fill up even a 4 GB flash disk with any reasonable performance.
Thanks, Tom