Maybe I'll read up on FAT16 and see what I can find...
I'm not a FAT16 or 32 expert but the free space of the SD card with corrupted files from NR2+ takes into account the corrupted files. So, I think somewhere in the FAT there is the information that a sector is not free or something like that.
For your problem with your long file, I would say that there is a sector that does not belong to your MP4 file (a thm file or an old file...)
Today, I'm working on a solution to avoid that kind of stuff : electronic DIY to wait 5-10 seconds after the power off :
switch on -> camera on -> 5 sec later NR2+ on
switch off -> camera off (NR2+ writes correctly the file) -> 5 sec later NR2+ off
The solution is very cheap with 2 transistors, some resithors and capacities,
I will write something on it if I have enough time.
Nekenk.