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Werner, you are right, du is not the problem, I restart from the begging again and now it generated without error using -b on compress ( i think using -L -2, also should works). Probrably i did...

Tried -b and also "-L -2" ,without success, continue generating 4306MB

tried with L 2, do diference either in time either in size ... how about -B, any influence on size?

Werner, I think we have an issue before the create_compressed_fs .
Just after finishing the step on script number 1 ... cp -rp /KNOPPIX/* $PFAD/knx/source/KNOPPIX, and running du on source and...

I understand the workaround, but what i'm trying to understand is why remastering the original DVD 7.2 without any change on chroot, change the size to more than 4GB