I thought I was going crazy here. I also recently made the jump to Mountain Lion on my data wrangling machine. Though I do have ShotPut Pro, XDCam Transfer, and P2CMS, I still prefer using the finder level copy routine to make my copies. I’ve noticed exactly the same behavior with both P2 and SxS cards.
My additional observations:
• This apparent file size increase ONLY occurs when there are sub-directories contained within the copied directory. If the directory only contains files, the file size remains correct. I can only hypothesize that this means that there is an increase in size of the hidden .ds_Store files contained in each directory.
• I’ve noticed that when copying to a FAT32 formatted drive (Windows), the directory size doesn’t change. This supports my .ds_Store theory, as those hidden files aren’t used on a Windows volume.
• The file size difference is ALWAYS larger than the original files. After comparing all of the files, and viewing them with their respective browsers to determine that nothing is missing, my takeaway is that as long as the copied directories are not SMALLER than the original, I’m okay. Of course, this is a poor substitute for the peace of mind of being able to see an exact match between the file sizes.