I've tested it with a 1GB file, the folder would not grow past 6MB in size.
The proposed solution of adding -disk-cache-dir=D:\location won't work. If so why has the download failed? Surely I don't need double the space to download any given file? Under F:\big-files\ there is a new directory structure Default\ which contains Default\Cache and 'Default\Code Cache'. Should I just set my cache to F:\big-files so the cache is the destination and be done with it, or is that also doomed for some reason? I think it will work because the move just needs to change the file pointer and not physically move the file, but if that's wrong, how to successfully download the file?
My question is (without downloading for days to find out): Will Chrome successfully move the file from F:\big-cache\ to F:\big-files\ when the file occupies 90% of the space available on the drive? Research suggests adding -disk-cache-dir='F:\big-cache' to the program shortcut. It appears that Chrome uses a temporary folder for downloads which would be on C:\somewhere (%appdata%\whatever) which has nowhere near enough space. On Windows 7 running Chrome browser, downloading a 3.2TB file to a USB drive say F:\big-files\ with 3.5TB free fails because 'Disk Full'.