mirror of
https://github.com/Start9Labs/start-os.git
synced 2026-03-26 02:11:53 +00:00
fix: raspberry pi image build improvements
- 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
@@ -1,7 +1,6 @@
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#!/bin/bash
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set -e
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MAX_IMG_LEN=$((4 * 1024 * 1024 * 1024)) # 4GB
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echo "==== StartOS Image Build ===="
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@@ -332,10 +331,10 @@ fi
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if [ "${IB_TARGET_PLATFORM}" = "raspberrypi" ]; then
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ln -sf /usr/bin/pi-beep /usr/local/bin/beep
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sh /boot/config.sh > /boot/config.txt
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sh /boot/firmware/config.sh > /boot/firmware/config.txt
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mkinitramfs -c gzip -o /boot/initrd.img-${RPI_KERNEL_VERSION}-rpi-v8 ${RPI_KERNEL_VERSION}-rpi-v8
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mkinitramfs -c gzip -o /boot/initrd.img-${RPI_KERNEL_VERSION}-rpi-2712 ${RPI_KERNEL_VERSION}-rpi-2712
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cp /usr/lib/u-boot/rpi_arm64/u-boot.bin /boot/u-boot.bin
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cp /usr/lib/u-boot/rpi_arm64/u-boot.bin /boot/firmware/u-boot.bin
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fi
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useradd --shell /bin/bash -G startos -m start9
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@@ -411,7 +410,16 @@ elif [ "${IMAGE_TYPE}" = img ]; then
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BOOT_LEN=$((2 * 1024 * 1024 * 1024))
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BOOT_END=$((BOOT_START + BOOT_LEN - 1))
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ROOT_START=$((BOOT_END + 1))
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ROOT_LEN=$((MAX_IMG_LEN - ROOT_START))
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# Size root partition to fit the squashfs + 256MB overhead for btrfs
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# metadata and config overlay, avoiding the need for btrfs resize
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SQUASHFS_SIZE=$(stat -c %s $prep_results_dir/binary/live/filesystem.squashfs)
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ROOT_LEN=$(( SQUASHFS_SIZE + 256 * 1024 * 1024 ))
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# Align to sector boundary
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ROOT_LEN=$(( (ROOT_LEN + SECTOR_LEN - 1) / SECTOR_LEN * SECTOR_LEN ))
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# Total image: partitions + GPT backup header (34 sectors)
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IMG_LEN=$((ROOT_START + ROOT_LEN + 34 * SECTOR_LEN))
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# Fixed GPT partition UUIDs (deterministic, based on old MBR disk ID cb15ae4d)
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FW_UUID=cb15ae4d-0001-4000-8000-000000000001
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@@ -420,7 +428,7 @@ elif [ "${IMAGE_TYPE}" = img ]; then
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ROOT_UUID=cb15ae4d-0004-4000-8000-000000000004
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TARGET_NAME=$prep_results_dir/${IMAGE_BASENAME}.img
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truncate -s $MAX_IMG_LEN $TARGET_NAME
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truncate -s $IMG_LEN $TARGET_NAME
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sfdisk $TARGET_NAME <<-EOF
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label: gpt
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@@ -431,10 +439,23 @@ elif [ "${IMAGE_TYPE}" = img ]; then
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${TARGET_NAME}4 : start=$((ROOT_START / SECTOR_LEN)), size=$((ROOT_LEN / SECTOR_LEN)), type=B921B045-1DF0-41C3-AF44-4C6F280D3FAE, uuid=${ROOT_UUID}, name="root"
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EOF
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FW_DEV=$(losetup --show -f --offset $FW_START --sizelimit $FW_LEN $TARGET_NAME)
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ESP_DEV=$(losetup --show -f --offset $ESP_START --sizelimit $ESP_LEN $TARGET_NAME)
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BOOT_DEV=$(losetup --show -f --offset $BOOT_START --sizelimit $BOOT_LEN $TARGET_NAME)
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ROOT_DEV=$(losetup --show -f --offset $ROOT_START --sizelimit $ROOT_LEN $TARGET_NAME)
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# Create named loop device nodes (high minor numbers to avoid conflicts)
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# and detach any stale ones from previous failed builds
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FW_DEV=/dev/startos-loop-fw
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ESP_DEV=/dev/startos-loop-esp
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BOOT_DEV=/dev/startos-loop-boot
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ROOT_DEV=/dev/startos-loop-root
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for dev in $FW_DEV:200 $ESP_DEV:201 $BOOT_DEV:202 $ROOT_DEV:203; do
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name=${dev%:*}
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minor=${dev#*:}
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[ -e $name ] || mknod $name b 7 $minor
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losetup -d $name 2>/dev/null || true
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done
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losetup $FW_DEV --offset $FW_START --sizelimit $FW_LEN $TARGET_NAME
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losetup $ESP_DEV --offset $ESP_START --sizelimit $ESP_LEN $TARGET_NAME
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losetup $BOOT_DEV --offset $BOOT_START --sizelimit $BOOT_LEN $TARGET_NAME
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losetup $ROOT_DEV --offset $ROOT_START --sizelimit $ROOT_LEN $TARGET_NAME
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mkfs.vfat -F32 -n firmware $FW_DEV
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mkfs.vfat -F32 -n efi $ESP_DEV
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@@ -447,18 +468,16 @@ elif [ "${IMAGE_TYPE}" = img ]; then
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BOOT_STAGING=$(mktemp -d)
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unsquashfs -n -f -d $BOOT_STAGING $prep_results_dir/binary/live/filesystem.squashfs boot
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# Mount partitions
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mkdir -p $TMPDIR/firmware $TMPDIR/efi $TMPDIR/boot $TMPDIR/root
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mount $FW_DEV $TMPDIR/firmware
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mount $ESP_DEV $TMPDIR/efi
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# Mount partitions (nested: firmware and efi inside boot)
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mkdir -p $TMPDIR/boot $TMPDIR/root
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mount $BOOT_DEV $TMPDIR/boot
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mkdir -p $TMPDIR/boot/firmware $TMPDIR/boot/efi
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mount $FW_DEV $TMPDIR/boot/firmware
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mount $ESP_DEV $TMPDIR/boot/efi
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mount $ROOT_DEV $TMPDIR/root
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# Split boot files: firmware to Part 1, kernels/initramfs to Part 3 (/boot)
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cp -a $BOOT_STAGING/boot/. $TMPDIR/firmware/
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for f in $TMPDIR/firmware/vmlinuz-* $TMPDIR/firmware/initrd.img-* $TMPDIR/firmware/System.map-* $TMPDIR/firmware/config-*; do
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[ -e "$f" ] && mv "$f" $TMPDIR/boot/
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done
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# Copy boot files — nested mounts route firmware/* to the firmware partition
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cp -a $BOOT_STAGING/boot/. $TMPDIR/boot/
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rm -rf $BOOT_STAGING
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mkdir $TMPDIR/root/images $TMPDIR/root/config
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@@ -475,11 +494,9 @@ elif [ "${IMAGE_TYPE}" = img ]; then
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rsync -a $SOURCE_DIR/raspberrypi/img/ $TMPDIR/next/
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# Install GRUB: ESP at /boot/efi (Part 2), /boot (Part 3)
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mkdir -p $TMPDIR/next/boot $TMPDIR/next/boot/efi $TMPDIR/next/boot/firmware \
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mkdir -p $TMPDIR/next/boot \
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$TMPDIR/next/dev $TMPDIR/next/proc $TMPDIR/next/sys $TMPDIR/next/media/startos/root
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mount --bind $TMPDIR/boot $TMPDIR/next/boot
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mount --bind $TMPDIR/efi $TMPDIR/next/boot/efi
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mount --bind $TMPDIR/firmware $TMPDIR/next/boot/firmware
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mount --rbind $TMPDIR/boot $TMPDIR/next/boot
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mount --bind /dev $TMPDIR/next/dev
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mount --bind /proc $TMPDIR/next/proc
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mount --bind /sys $TMPDIR/next/sys
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@@ -492,9 +509,7 @@ elif [ "${IMAGE_TYPE}" = img ]; then
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umount $TMPDIR/next/sys
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umount $TMPDIR/next/proc
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umount $TMPDIR/next/dev
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umount $TMPDIR/next/boot/firmware
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umount $TMPDIR/next/boot/efi
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umount $TMPDIR/next/boot
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umount -l $TMPDIR/next/boot
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# Fix root= in grub.cfg: update-grub sees loop devices, but the
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# real device uses a fixed GPT PARTUUID for root (Part 4).
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@@ -507,39 +522,16 @@ elif [ "${IMAGE_TYPE}" = img ]; then
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umount $TMPDIR/next
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umount $TMPDIR/lower
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umount $TMPDIR/firmware
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umount $TMPDIR/efi
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umount $TMPDIR/boot/firmware
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umount $TMPDIR/boot/efi
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umount $TMPDIR/boot
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umount $TMPDIR/root
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# Shrink btrfs to minimum size
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SHRINK_MNT=$(mktemp -d)
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mount $ROOT_DEV $SHRINK_MNT
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btrfs filesystem resize min $SHRINK_MNT
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umount $SHRINK_MNT
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rmdir $SHRINK_MNT
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ROOT_LEN=$(btrfs inspect-internal dump-super $ROOT_DEV | awk '/^total_bytes/ {print $2}')
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losetup -d $ROOT_DEV
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losetup -d $BOOT_DEV
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losetup -d $ESP_DEV
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losetup -d $FW_DEV
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# Recreate partition table with shrunk root
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sfdisk $TARGET_NAME <<-EOF
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label: gpt
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${TARGET_NAME}1 : start=$((FW_START / SECTOR_LEN)), size=$((FW_LEN / SECTOR_LEN)), type=EBD0A0A2-B9E5-4433-87C0-68B6B72699C7, uuid=${FW_UUID}, name="firmware"
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${TARGET_NAME}2 : start=$((ESP_START / SECTOR_LEN)), size=$((ESP_LEN / SECTOR_LEN)), type=C12A7328-F81F-11D2-BA4B-00A0C93EC93B, uuid=${ESP_UUID}, name="efi"
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${TARGET_NAME}3 : start=$((BOOT_START / SECTOR_LEN)), size=$((BOOT_LEN / SECTOR_LEN)), type=0FC63DAF-8483-4772-8E79-3D69D8477DE4, uuid=${BOOT_UUID}, name="boot"
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${TARGET_NAME}4 : start=$((ROOT_START / SECTOR_LEN)), size=$((ROOT_LEN / SECTOR_LEN)), type=B921B045-1DF0-41C3-AF44-4C6F280D3FAE, uuid=${ROOT_UUID}, name="root"
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EOF
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TARGET_SIZE=$((ROOT_START + ROOT_LEN))
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truncate -s $TARGET_SIZE $TARGET_NAME
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# Move backup GPT to new end of disk after truncation
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sgdisk -e $TARGET_NAME
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mv $TARGET_NAME $RESULTS_DIR/$IMAGE_BASENAME.img
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fi
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