This issue got mostly eliminated with a contributor's code change in 5.0.3 
(I can't remember who but this has been really helpful to me at least).

You'll notice the two numbers differ by exactly one, so somebody built a 
patch to have it just fix the inconsistency and continue appending to the 
volume w/o marking the volume in error.

    Bob

> From: dmbo <bacula-forum AT backupcentral DOT com>
> Subject: [Bacula-users]  Storage error: "The sizes do not match!"
> To: bacula-users AT lists.sourceforge DOT net
> Message-ID: <1291857583.m2f.348248 AT www.backupcentral DOT com>
>
> Hi,
>
> I am using bacula for a couple of days. It works perfect, except one thing: 
> from time to time I get this message:
> 09-&#1044;&#1077;&#1082; 10&#58;05 sl03500008066-sd JobId 335&#58; Error&#58; 
> Bacula cannot write on disk Volume "nas101l4" because&#58; The sizes do not 
> match! Volume=12487974757 Catalog=11999231858
> Then I should use "label" bconsole command that creates a new file.
>
> How to solve this problem?
>
> Yes, I googled it, no result so far. There are lots of topics about it but 
> without solution.
>


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