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I tried to upx pack the executable file built with JSmooth 0.9.9-7. This ended up in the error message "section size problem".
Files which are packed with JSmooth 0.9.7, work perfectly, so there seems to be some change in the resulting exe file since these two versions.
Maybe someone has a clue. I appreciate every hint that leads to a solution.
Most likely this is because the last section's virtual address offset plus section size has exceeded the size of the image.
To fix by hand, use a PE editor to modify the image size using this formula:
(floor(original image size / 4096) + 1) * 4096
For example, if the image size is 1035891 (0xFCE73), modify it to 1036288 (0xFD000).
Then UPX should be happy about it.
Alternately, Launch4j doesn't have this problem.