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fix: raspberry pi image build improvements

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- Move firmware config files to boot/firmware/ to match raspi-firmware
  package layout in Debian Trixie
- Use nested mounts (firmware and efi inside boot) so squashfs boot
  files land on the correct partitions without manual splitting
- Pre-calculate root partition size from squashfs instead of creating
  oversized btrfs and shrinking (avoids ioctl failure on loop devices)
- Use named loop devices (/dev/startos-loop-*) with automatic cleanup
  of stale devices from previous failed builds
- Use --rbind for /boot in upgrade scripts so nested mounts (efi,
  firmware) are automatically carried into the chroot
This commit is contained in:
Aiden McClelland
2026-03-13 12:08:49 -06:00
parent a81b1aa5a6
commit fc4b887b71
5 changed files with 46 additions and 59 deletions
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92
build/image-recipe/build.sh
View File

@@ -1,7 +1,6 @@
#!/bin/bash
set -e
MAX_IMG_LEN=$((4 * 1024 * 1024 * 1024)) # 4GB
echo "==== StartOS Image Build ===="
@@ -332,10 +331,10 @@ fi
if [ "${IB_TARGET_PLATFORM}" = "raspberrypi" ]; then
ln -sf /usr/bin/pi-beep /usr/local/bin/beep
sh /boot/config.sh > /boot/config.txt
sh /boot/firmware/config.sh > /boot/firmware/config.txt
mkinitramfs -c gzip -o /boot/initrd.img-${RPI_KERNEL_VERSION}-rpi-v8 ${RPI_KERNEL_VERSION}-rpi-v8
mkinitramfs -c gzip -o /boot/initrd.img-${RPI_KERNEL_VERSION}-rpi-2712 ${RPI_KERNEL_VERSION}-rpi-2712
cp /usr/lib/u-boot/rpi_arm64/u-boot.bin /boot/u-boot.bin
cp /usr/lib/u-boot/rpi_arm64/u-boot.bin /boot/firmware/u-boot.bin
fi
useradd --shell /bin/bash -G startos -m start9
@@ -411,7 +410,16 @@ elif [ "${IMAGE_TYPE}" = img ]; then
BOOT_LEN=$((2 * 1024 * 1024 * 1024))
BOOT_END=$((BOOT_START + BOOT_LEN - 1))
ROOT_START=$((BOOT_END + 1))
ROOT_LEN=$((MAX_IMG_LEN - ROOT_START))
# Size root partition to fit the squashfs + 256MB overhead for btrfs
# metadata and config overlay, avoiding the need for btrfs resize
SQUASHFS_SIZE=$(stat -c %s $prep_results_dir/binary/live/filesystem.squashfs)
ROOT_LEN=$(( SQUASHFS_SIZE + 256 * 1024 * 1024 ))
# Align to sector boundary
ROOT_LEN=$(( (ROOT_LEN + SECTOR_LEN - 1) / SECTOR_LEN * SECTOR_LEN ))
# Total image: partitions + GPT backup header (34 sectors)
IMG_LEN=$((ROOT_START + ROOT_LEN + 34 * SECTOR_LEN))
# Fixed GPT partition UUIDs (deterministic, based on old MBR disk ID cb15ae4d)
FW_UUID=cb15ae4d-0001-4000-8000-000000000001
@@ -420,7 +428,7 @@ elif [ "${IMAGE_TYPE}" = img ]; then
ROOT_UUID=cb15ae4d-0004-4000-8000-000000000004
TARGET_NAME=$prep_results_dir/${IMAGE_BASENAME}.img
truncate -s $MAX_IMG_LEN $TARGET_NAME
truncate -s $IMG_LEN $TARGET_NAME
sfdisk $TARGET_NAME <<-EOF
label: gpt
@@ -431,10 +439,23 @@ elif [ "${IMAGE_TYPE}" = img ]; then
${TARGET_NAME}4 : start=$((ROOT_START / SECTOR_LEN)), size=$((ROOT_LEN / SECTOR_LEN)), type=B921B045-1DF0-41C3-AF44-4C6F280D3FAE, uuid=${ROOT_UUID}, name="root"
EOF
FW_DEV=$(losetup --show -f --offset $FW_START --sizelimit $FW_LEN $TARGET_NAME)
ESP_DEV=$(losetup --show -f --offset $ESP_START --sizelimit $ESP_LEN $TARGET_NAME)
BOOT_DEV=$(losetup --show -f --offset $BOOT_START --sizelimit $BOOT_LEN $TARGET_NAME)
ROOT_DEV=$(losetup --show -f --offset $ROOT_START --sizelimit $ROOT_LEN $TARGET_NAME)
# Create named loop device nodes (high minor numbers to avoid conflicts)
# and detach any stale ones from previous failed builds
FW_DEV=/dev/startos-loop-fw
ESP_DEV=/dev/startos-loop-esp
BOOT_DEV=/dev/startos-loop-boot
ROOT_DEV=/dev/startos-loop-root
for dev in $FW_DEV:200 $ESP_DEV:201 $BOOT_DEV:202 $ROOT_DEV:203; do
name=${dev%:*}
minor=${dev#*:}
[ -e $name ] || mknod $name b 7 $minor
losetup -d $name 2>/dev/null || true
done
losetup $FW_DEV --offset $FW_START --sizelimit $FW_LEN $TARGET_NAME
losetup $ESP_DEV --offset $ESP_START --sizelimit $ESP_LEN $TARGET_NAME
losetup $BOOT_DEV --offset $BOOT_START --sizelimit $BOOT_LEN $TARGET_NAME
losetup $ROOT_DEV --offset $ROOT_START --sizelimit $ROOT_LEN $TARGET_NAME
mkfs.vfat -F32 -n firmware $FW_DEV
mkfs.vfat -F32 -n efi $ESP_DEV
@@ -447,18 +468,16 @@ elif [ "${IMAGE_TYPE}" = img ]; then
BOOT_STAGING=$(mktemp -d)
unsquashfs -n -f -d $BOOT_STAGING $prep_results_dir/binary/live/filesystem.squashfs boot
# Mount partitions
mkdir -p $TMPDIR/firmware $TMPDIR/efi $TMPDIR/boot $TMPDIR/root
mount $FW_DEV $TMPDIR/firmware
mount $ESP_DEV $TMPDIR/efi
# Mount partitions (nested: firmware and efi inside boot)
mkdir -p $TMPDIR/boot $TMPDIR/root
mount $BOOT_DEV $TMPDIR/boot
mkdir -p $TMPDIR/boot/firmware $TMPDIR/boot/efi
mount $FW_DEV $TMPDIR/boot/firmware
mount $ESP_DEV $TMPDIR/boot/efi
mount $ROOT_DEV $TMPDIR/root
# Split boot files: firmware to Part 1, kernels/initramfs to Part 3 (/boot)
cp -a $BOOT_STAGING/boot/. $TMPDIR/firmware/
for f in $TMPDIR/firmware/vmlinuz-* $TMPDIR/firmware/initrd.img-* $TMPDIR/firmware/System.map-* $TMPDIR/firmware/config-*; do
[ -e "$f" ] && mv "$f" $TMPDIR/boot/
done
# Copy boot files — nested mounts route firmware/* to the firmware partition
cp -a $BOOT_STAGING/boot/. $TMPDIR/boot/
rm -rf $BOOT_STAGING
mkdir $TMPDIR/root/images $TMPDIR/root/config
@@ -475,11 +494,9 @@ elif [ "${IMAGE_TYPE}" = img ]; then
rsync -a $SOURCE_DIR/raspberrypi/img/ $TMPDIR/next/
# Install GRUB: ESP at /boot/efi (Part 2), /boot (Part 3)
mkdir -p $TMPDIR/next/boot $TMPDIR/next/boot/efi $TMPDIR/next/boot/firmware \
mkdir -p $TMPDIR/next/boot \
$TMPDIR/next/dev $TMPDIR/next/proc $TMPDIR/next/sys $TMPDIR/next/media/startos/root
mount --bind $TMPDIR/boot $TMPDIR/next/boot
mount --bind $TMPDIR/efi $TMPDIR/next/boot/efi
mount --bind $TMPDIR/firmware $TMPDIR/next/boot/firmware
mount --rbind $TMPDIR/boot $TMPDIR/next/boot
mount --bind /dev $TMPDIR/next/dev
mount --bind /proc $TMPDIR/next/proc
mount --bind /sys $TMPDIR/next/sys
@@ -492,9 +509,7 @@ elif [ "${IMAGE_TYPE}" = img ]; then
umount $TMPDIR/next/sys
umount $TMPDIR/next/proc
umount $TMPDIR/next/dev
umount $TMPDIR/next/boot/firmware
umount $TMPDIR/next/boot/efi
umount $TMPDIR/next/boot
umount -l $TMPDIR/next/boot
# Fix root= in grub.cfg: update-grub sees loop devices, but the
# real device uses a fixed GPT PARTUUID for root (Part 4).
@@ -507,39 +522,16 @@ elif [ "${IMAGE_TYPE}" = img ]; then
umount $TMPDIR/next
umount $TMPDIR/lower
umount $TMPDIR/firmware
umount $TMPDIR/efi
umount $TMPDIR/boot/firmware
umount $TMPDIR/boot/efi
umount $TMPDIR/boot
umount $TMPDIR/root
# Shrink btrfs to minimum size
SHRINK_MNT=$(mktemp -d)
mount $ROOT_DEV $SHRINK_MNT
btrfs filesystem resize min $SHRINK_MNT
umount $SHRINK_MNT
rmdir $SHRINK_MNT
ROOT_LEN=$(btrfs inspect-internal dump-super $ROOT_DEV | awk '/^total_bytes/ {print $2}')
losetup -d $ROOT_DEV
losetup -d $BOOT_DEV
losetup -d $ESP_DEV
losetup -d $FW_DEV
# Recreate partition table with shrunk root
sfdisk $TARGET_NAME <<-EOF
label: gpt
${TARGET_NAME}1 : start=$((FW_START / SECTOR_LEN)), size=$((FW_LEN / SECTOR_LEN)), type=EBD0A0A2-B9E5-4433-87C0-68B6B72699C7, uuid=${FW_UUID}, name="firmware"
${TARGET_NAME}2 : start=$((ESP_START / SECTOR_LEN)), size=$((ESP_LEN / SECTOR_LEN)), type=C12A7328-F81F-11D2-BA4B-00A0C93EC93B, uuid=${ESP_UUID}, name="efi"
${TARGET_NAME}3 : start=$((BOOT_START / SECTOR_LEN)), size=$((BOOT_LEN / SECTOR_LEN)), type=0FC63DAF-8483-4772-8E79-3D69D8477DE4, uuid=${BOOT_UUID}, name="boot"
${TARGET_NAME}4 : start=$((ROOT_START / SECTOR_LEN)), size=$((ROOT_LEN / SECTOR_LEN)), type=B921B045-1DF0-41C3-AF44-4C6F280D3FAE, uuid=${ROOT_UUID}, name="root"
EOF
TARGET_SIZE=$((ROOT_START + ROOT_LEN))
truncate -s $TARGET_SIZE $TARGET_NAME
# Move backup GPT to new end of disk after truncation
sgdisk -e $TARGET_NAME
mv $TARGET_NAME $RESULTS_DIR/$IMAGE_BASENAME.img
fi

0
build/image-recipe/raspberrypi/squashfs/boot/config.sh → build/image-recipe/raspberrypi/squashfs/boot/firmware/config.sh
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0
build/image-recipe/raspberrypi/squashfs/boot/config.txt → build/image-recipe/raspberrypi/squashfs/boot/firmware/config.txt
View File

2
build/lib/scripts/chroot-and-upgrade
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@@ -34,7 +34,7 @@ set -- "${POSITIONAL_ARGS[@]}" # restore positional parameters
if [ -z "$NO_SYNC" ]; then
echo 'Syncing...'
umount -R /media/startos/next 2> /dev/null
umount -l /media/startos/next 2> /dev/null
umount /media/startos/upper 2> /dev/null
rm -rf /media/startos/upper /media/startos/next
mkdir /media/startos/upper

11
build/lib/scripts/upgrade
View File

@@ -24,7 +24,7 @@ fi
unsquashfs -f -d / $1 boot
umount -R /media/startos/next 2> /dev/null || true
umount -l /media/startos/next 2> /dev/null || true
umount /media/startos/upper 2> /dev/null || true
umount /media/startos/lower 2> /dev/null || true
@@ -47,14 +47,9 @@ mount --bind /tmp /media/startos/next/tmp
mount --bind /dev /media/startos/next/dev
mount --bind /sys /media/startos/next/sys
mount --bind /proc /media/startos/next/proc
mount --bind /boot /media/startos/next/boot
mount --rbind /boot /media/startos/next/boot
mount --bind /media/startos/root /media/startos/next/media/startos/root
if mountpoint /boot/efi 2>&1 > /dev/null; then
mkdir -p /media/startos/next/boot/efi
mount --bind /boot/efi /media/startos/next/boot/efi
fi
if mountpoint /sys/firmware/efi/efivars 2>&1 > /dev/null; then
mount --bind /sys/firmware/efi/efivars /media/startos/next/sys/firmware/efi/efivars
fi
@@ -79,7 +74,7 @@ SIGN_FILE="$(ls -1 /media/startos/next/usr/lib/linux-kbuild-*/scripts/sign-file
sync
umount -Rl /media/startos/next
umount -l /media/startos/next
umount /media/startos/upper
umount /media/startos/lower