Hello everyone,

when replacing the Sound Database of the ROM with my edited one (the edited one is about 0.2MB/200KB bigger) I always face the problem that my ROM exceeds the 32MB cap (always becoming 34,4MB), therefore creating an Invalid Header.

Just wondering what exactly this invald header means (how do i get one, why does it occur, is this bad, can I still work with this without worrying) and if there are methods of avoiding this invalid header.
And why the new files size is 34,4MB while the Sound Database isn't even one MB bigger.

Greets
BooChewbaca
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previously (un)known as BooChewbaca

I have that too. But as long as it doesn't hurt the gameplay then I don't worry about it.
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Ignoring is not the best way, I did that too and suddendly my ROM was 500MB big after I imported the sdat which made no sense to me but well, it happened. I worked around it that I made a .nmp patch of my hack and reimported it and replaced the sdat file only once. Then ROM size was normal and I released the xdelta.
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Super Mario Castle 2 | Full release

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A nmp patch does not apply ASM hacks and Overlay edits, or does it? As far as I know it only applies changed tiles(ets), backgrounds and levels.
Either way, I'll try this out later. At worst I have to apply all the ASM hacks again.
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previously (un)known as BooChewbaca

.nmp doesn't apply ASM hacks, not sure about overlay edits
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Of course it doesn't, I added them manually afterwards. I'm sure there is a hacky way to solve that problem easier but as long as there isn't one posted I guess that is the only way.
_________________________
Super Mario Bros. - The New Worlds | Full release
Super Mario Castle 2 | Full release

My Youtube channel
Best friends forever

What tool gives you the "invalid header" error?

It might be becuase the "device capacity" field at offset 0x14 is not updated. (see here)

NSMB has it set to 8, which means 32MB. If the ROM is bigger than 32MB, that field should be increased.
Try increasing it to 9 (64MB) or 10 (128MB) maybe?

If that doesn't fix it, I don't know what's the issue.

I used NSMBe (latest version) to replace the Sound Database. This Database was edited with Nitro Studio.
If I encounter that error again, I might try this, thanks.

But for now, rebuilding the ROM like Arceus suggested helped.
The ROM now has a valid header and new music.
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previously (un)known as BooChewbaca