Hi PB,
This is my situation. (N810-OS 43-7)
I cloned twice in my external 16GB
First time I partitioned FAT=192MB, Swap=256MB, Ext3=remaining
I got an internal memory around 15.5GB and external memory 192MB
I realized that my Wayfinder uses mmc2 to set the maps and mmc2 is my 192MB
So I cloned again: FAT=3GB, Swap=256MB, Ext3=remaining
I got an internal memory around 12GB and external memory 3GB
No more problem now with my Wayfinder.

The only problem I had in both cloning is with my swap.
I type "free" and I get "0".
I do swapon /dev/mmcblk1p3 and I get my 256 MB, which remain in the mean time I don't turn the N810 off.
If I turn it off, I loose my swap and I need to use "swapon" again.
Any options?
Thank you