Trying to transfer files to flash drive, but getting 'no space left on device' despite having over 77 GB of free space

The command lists (and count) also the directory (.) and the parent directory (…), that’s okay. I think it’s the wrong filesystem for your project. Or you have to create a directory (maybe named “Data”) where you move all your files, because there’s a limit of maximum file- / directorynames in the root of your flash drive with vfat. And with many little files you’ve reached this number. I don’t use flash drives with vfat, so it’s just a thing I remembered from a few years ago.