Reported here https://github.com/bitcoin/bitcoin/pull/12629#issuecomment-381095603 by @Empact.  I've seen it now in a few different travis jobs, including:

https://travis-ci.org/bitcoin/bitcoin/jobs/366157920
https://travis-ci.org/bitcoin/bitcoin/jobs/366139851

From my initial investigation it seems like there may be an actual bug in block announcement, so I'm  opening this issue to track.
{
    pos.nFile = nFile;
    LOCK(cs_LastBlockFile);
    unsigned int nNewSize;
    pos.nPos = vinfoBlockFile[nFile].nUndoSize;
    nNewSize = vinfoBlockFile[nFile].nUndoSize += nAddSize;
    setDirtyFileInfo.insert(nFile);
    unsigned int nOldChunks = (pos.nPos + UNDOFILE_CHUNK_SIZE - 1) / UNDOFILE_CHUNK_SIZE;
    unsigned int nNewChunks = (nNewSize + UNDOFILE_CHUNK_SIZE - 1) / UNDOFILE_CHUNK_SIZE;
    if (nNewChunks > nOldChunks) {
        if (fPruneMode)
            fCheckForPruning = true;
        if (CheckDiskSpace(nNewChunks * UNDOFILE_CHUNK_SIZE - pos.nPos, true)) {
            FILE *file = OpenUndoFile(pos);
            if (file) {
                LogPrintf("Pre-allocating up to position 0x%x in rev%05u.dat\n", nNewChunks * UNDOFILE_CHUNK_SIZE, pos.nFile);
                AllocateFileRange(file, pos.nPos, nNewChunks * UNDOFILE_CHUNK_SIZE - pos.nPos);
                fclose(file);
            }
        }
        else
            return state.Error("out of disk space");
    }
    return true;
}
static bool CheckBlockHeader(const CBlockHeader& block, CValidationState& state, const Consensus::Params& consensusParams, bool fCheckPOW = true)