The error is intermittent. Over the weekend the copying between the 64-bit master and the 64-bit slave also failed
Here is the trace.
FATAL: hudson.util.IOException2: Not in GZIP format
21:16:23 stream=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
21:16:23 hudson.util.IOException2: hudson.util.IOException2: Not in GZIP format
21:16:23 stream=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
21:16:23 at com.michelin.cio.hudson.plugins.copytoslave.MyFilePath.copyRecursiveTo(MyFilePath.java:94)
21:16:23 at com.michelin.cio.hudson.plugins.copytoslave.CopyToSlaveBuildWrapper.setUp(CopyToSlaveBuildWrapper.java:94)
21:16:23 at hudson.model.Build$RunnerImpl.doRun(Build.java:131)
21:16:23 at hudson.model.AbstractBuild$AbstractRunner.run(AbstractBuild.java:417)
21:16:23 at hudson.model.Run.run(Run.java:1365)
21:16:23 at hudson.model.FreeStyleBuild.run(FreeStyleBuild.java:46)
21:16:23 at hudson.model.ResourceController.execute(ResourceController.java:88)
21:16:23 at hudson.model.Executor.run(Executor.java:145)
21:16:23 Caused by: java.util.concurrent.ExecutionException: hudson.util.IOException2: Not in GZIP format
21:16:23 stream=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
21:16:23 at hudson.remoting.Channel$2.adapt(Channel.java:662)
21:16:23 at hudson.remoting.Channel$2.adapt(Channel.java:657)
21:16:23 at hudson.remoting.FutureAdapter.get(FutureAdapter.java:55)
21:16:23 at com.michelin.cio.hudson.plugins.copytoslave.MyFilePath.copyRecursiveTo(MyFilePath.java:92)
21:16:23 ... 7 more
21:16:23 Caused by: hudson.util.IOException2: Not in GZIP format
21:16:23 stream=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
21:16:23 at hudson.FilePath$TarCompression$2.extract(FilePath.java:537)
21:16:23 at com.michelin.cio.hudson.plugins.copytoslave.MyFilePath$1.invoke(MyFilePath.java:82)
21:16:23 at com.michelin.cio.hudson.plugins.copytoslave.MyFilePath$1.invoke(MyFilePath.java:77)
21:16:23 at hudson.FilePath$FileCallableWrapper.call(FilePath.java:1925)
21:16:23 at hudson.remoting.UserRequest.perform(UserRequest.java:114)
21:16:23 at hudson.remoting.UserRequest.perform(UserRequest.java:48)
21:16:23 at hudson.remoting.Request$2.run(Request.java:270)
21:16:23 at java.util.concurrent.Executors$RunnableAdapter.call(Executors.java:471)
21:16:23 at java.util.concurrent.FutureTask$Sync.innerRun(FutureTask.java:334)
21:16:23 at java.util.concurrent.FutureTask.run(FutureTask.java:166)
21:16:23 at java.util.concurrent.ThreadPoolExecutor.runWorker(ThreadPoolExecutor.java:1110)
21:16:23 at java.util.concurrent.ThreadPoolExecutor$Worker.run(ThreadPoolExecutor.java:603)
21:16:23 at java.lang.Thread.run(Thread.java:636)
21:16:23 Caused by: java.io.IOException: Not in GZIP format
21:16:23 at java.util.zip.GZIPInputStream.readHeader(GZIPInputStream.java:154)
21:16:23 at java.util.zip.GZIPInputStream.<init>(GZIPInputStream.java:75)
21:16:23 at hudson.FilePath$TarCompression$2.extract(FilePath.java:533)
21:16:23 ... 12 more

Copying a compressed tar file from a 64-bit master to a 32-bit slave
When copying a compressed tar file, such as myfile.gar.gz from master to slave I get the following error.
Part of the file gets copied (always the same amount) before the copying fails.
Started by user ullamerz
Building remotely on bcbl10
Copying 'tar/adps_dev.tar.gz', excluding '' from 'file:/hudson/server/' on the master to 'file:/hudson/server/workspace/copy-tar/' on 'bcbl10'.
FATAL: null
java.lang.NegativeArraySizeException
at hudson.remoting.ProxyOutputStream$Chunk.<init>(ProxyOutputStream.java:175)
at hudson.remoting.ProxyOutputStream._write(ProxyOutputStream.java:123)
at hudson.remoting.ProxyOutputStream.write(ProxyOutputStream.java:103)
at java.io.BufferedOutputStream.flushBuffer(BufferedOutputStream.java:82)
at java.io.BufferedOutputStream.write(BufferedOutputStream.java:126)
at java.util.zip.DeflaterOutputStream.deflate(DeflaterOutputStream.java:178)
at java.util.zip.DeflaterOutputStream.write(DeflaterOutputStream.java:135)
at java.util.zip.GZIPOutputStream.write(GZIPOutputStream.java:89)
at java.io.BufferedOutputStream.write(BufferedOutputStream.java:122)
at org.apache.tools.tar.TarBuffer.writeBlock(TarBuffer.java:410)
at org.apache.tools.tar.TarBuffer.writeRecord(TarBuffer.java:388)
at hudson.org.apache.tools.tar.TarOutputStream.write(TarOutputStream.java:337)
at hudson.util.io.TarArchiver.visit(TarArchiver.java:103)
at com.michelin.cio.hudson.plugins.copytoslave.MyGlobDirScanner.scan(MyGlobDirScanner.java:68)
at com.michelin.cio.hudson.plugins.copytoslave.MyFilePath.writeToTar(MyFilePath.java:173)
at com.michelin.cio.hudson.plugins.copytoslave.MyFilePath.copyRecursiveTo(MyFilePath.java:90)
at com.michelin.cio.hudson.plugins.copytoslave.CopyToSlaveBuildWrapper.setUp(CopyToSlaveBuildWrapper.java:94)
at hudson.model.Build$RunnerImpl.doRun(Build.java:131)
at hudson.model.AbstractBuild$AbstractRunner.run(AbstractBuild.java:417)
at hudson.model.Run.run(Run.java:1365)
at hudson.model.FreeStyleBuild.run(FreeStyleBuild.java:46)
at hudson.model.ResourceController.execute(ResourceController.java:88)
at hudson.model.Executor.run(Executor.java:145)
Once or twice I also received this error; but the error showing below does not persist
tarted by user ullamerz
Building remotely on bcbl10
Copying 'tar/adps_dev.tar.gz', excluding '' from 'file:/hudson/server/' on the master to 'file:/hudson/server/workspace/copy-tar/' on 'bcbl10'.
FATAL: hudson.util.IOException2: Failed to extract /hudson/server/tar/adps_dev.tar.gz
hudson.util.IOException2: hudson.util.IOException2: Failed to extract /hudson/server/tar/adps_dev.tar.gz
at com.michelin.cio.hudson.plugins.copytoslave.MyFilePath.copyRecursiveTo(MyFilePath.java:94)
at com.michelin.cio.hudson.plugins.copytoslave.CopyToSlaveBuildWrapper.setUp(CopyToSlaveBuildWrapper.java:94)
at hudson.model.Build$RunnerImpl.doRun(Build.java:131)
at hudson.model.AbstractBuild$AbstractRunner.run(AbstractBuild.java:417)
at hudson.model.Run.run(Run.java:1365)
at hudson.model.FreeStyleBuild.run(FreeStyleBuild.java:46)
at hudson.model.ResourceController.execute(ResourceController.java:88)
at hudson.model.Executor.run(Executor.java:145)
Caused by: java.util.concurrent.ExecutionException: hudson.util.IOException2: Failed to extract /hudson/server/tar/adps_dev.tar.gz
at hudson.remoting.Channel$2.adapt(Channel.java:662)
at hudson.remoting.Channel$2.adapt(Channel.java:657)
at hudson.remoting.FutureAdapter.get(FutureAdapter.java:55)
at com.michelin.cio.hudson.plugins.copytoslave.MyFilePath.copyRecursiveTo(MyFilePath.java:92)
... 7 more
Caused by: hudson.util.IOException2: Failed to extract /hudson/server/tar/adps_dev.tar.gz
at com.michelin.cio.hudson.plugins.copytoslave.MyFilePath.readFromTar(MyFilePath.java:158)
at com.michelin.cio.hudson.plugins.copytoslave.MyFilePath$1.invoke(MyFilePath.java:82)
at com.michelin.cio.hudson.plugins.copytoslave.MyFilePath$1.invoke(MyFilePath.java:77)
at hudson.FilePath$FileCallableWrapper.call(FilePath.java:1925)
at hudson.remoting.UserRequest.perform(UserRequest.java:114)
at hudson.remoting.UserRequest.perform(UserRequest.java:48)
at hudson.remoting.Request$2.run(Request.java:270)
at java.util.concurrent.Executors$RunnableAdapter.call(Executors.java:471)
at java.util.concurrent.FutureTask$Sync.innerRun(FutureTask.java:334)
at java.util.concurrent.FutureTask.run(FutureTask.java:166)
at java.util.concurrent.ThreadPoolExecutor.runWorker(ThreadPoolExecutor.java:1110)
at java.util.concurrent.ThreadPoolExecutor$Worker.run(ThreadPoolExecutor.java:603)
at java.lang.Thread.run(Thread.java:636)
Caused by: java.util.zip.ZipException: invalid stored block lengths
at java.util.zip.InflaterInputStream.read(InflaterInputStream.java:164)
at java.util.zip.GZIPInputStream.read(GZIPInputStream.java:109)
at org.apache.tools.tar.TarBuffer.readBlock(TarBuffer.java:257)
at org.apache.tools.tar.TarBuffer.readRecord(TarBuffer.java:223)
at hudson.org.apache.tools.tar.TarInputStream.read(TarInputStream.java:345)
at java.io.FilterInputStream.read(FilterInputStream.java:107)
at org.apache.commons.io.IOUtils.copyLarge(IOUtils.java:1025)
at org.apache.commons.io.IOUtils.copy(IOUtils.java:999)
at hudson.util.IOUtils.copy(IOUtils.java:33)
at com.michelin.cio.hudson.plugins.copytoslave.MyFilePath.readFromTar(MyFilePath.java:135)
... 12 more
The copying works fine using a 64bit slave with also SUSE 11.1
On the 32-bit slave I defined a pre-build script doing an scp from the master to the slave and this works consistently.