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I've just put a 512 byte binary file through a binary to Intel Hex conversion and the resulting Intel Hex file came out at 1,387 characters.
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You might wonder about the disparity between the file size quoted above and the buffer size of 1440 I mentioned the post before last - when I counted the number of characters in an Intel Hex file representing 512 bytes I counted exactly that - the number of characters. I forgot about the invisible CR/LF characters which may or may not both - depending on which OS saved the Intel Hex file - be present on the ends of the lines of hex. The actual length of the file is 1421 characters but I have allowed a small amount of wiggle room in case the Intel Hex file sent to the Arduino was acquired by cutting and pasting it from some online source, in which case there could be a few stray characters dangling off the end of it.