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I had a similar issue with a new batch of BBB not taking the image. It appears to me that a Rev C is not a Rev C. Or perhaps Rev C only refers to the hardware and not the OS installed. Using fdisk and looking at the partition of the eMMC my old board had 3867MB available (image created with this version). Using the new board the partition reported 3825MB. I found a third board that reported 3925MB. All boards purchased in the last year and a half I think.
So I made my partitions use about 150MB less so maybe it will work for a year or two.
So can anyone explain what is going on and what we need to do?
Interesting. I have to say I've not seen this problem, however, if I understand correctly, cloning is being used to copy the image from a working Rev.C BBB to other Rev.C BBBs? I guess I'm a little confused, as I'm wondering why? If you have a flasher-image on an sdcard, why wouldn't you just use that to flash each Rev.C board?
IN my case and probably others. I have created overlays for a custom cape. Added libraries, software, image etc. I documented it this time, but it took 2 hours to do it. Ok, I was side tracked some, but with cloning you turn it on and wait for the LEDs to stop blinking. Who cares if you get side tracked.