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kubesolo-os/build/scripts/create-disk-image.sh
Adolfo Delorenzo 09dcea84ef
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fix: disk image build, piCore64 URL, license
- Add kpartx for reliable loop partition mapping in Docker containers
- Fix piCore64 download URL (changed from .img.gz to .zip format)
- Fix piCore64 boot partition mount (initramfs on p1, not p2)
- Fix tar --wildcards for RPi firmware extraction
- Add MIT license (same as KubeSolo)
- Add kpartx and unzip to Docker builder image

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 17:05:03 -06:00

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#!/bin/bash
# create-disk-image.sh — Create a raw disk image with A/B system partitions
#
# Partition layout (GPT):
# Part 1: EFI/Boot (256 MB, FAT32) — GRUB + grubenv + A/B boot logic
# Part 2: System A (512 MB, ext4) — vmlinuz + kubesolo-os.gz (active)
# Part 3: System B (512 MB, ext4) — vmlinuz + kubesolo-os.gz (passive)
# Part 4: Data (remaining, ext4) — persistent K8s state
set -euo pipefail
SCRIPT_DIR="$(cd "$(dirname "${BASH_SOURCE[0]}")" && pwd)"
PROJECT_ROOT="$(cd "$SCRIPT_DIR/../.." && pwd)"
ROOTFS_DIR="${ROOTFS_DIR:-$PROJECT_ROOT/build/rootfs-work}"
OUTPUT_DIR="${OUTPUT_DIR:-$PROJECT_ROOT/output}"
VERSION="$(cat "$PROJECT_ROOT/VERSION")"
OS_NAME="kubesolo-os"
IMG_OUTPUT="$OUTPUT_DIR/${OS_NAME}-${VERSION}.img"
IMG_SIZE_MB="${IMG_SIZE_MB:-4096}" # 4 GB default (larger for A/B)
VMLINUZ="$ROOTFS_DIR/vmlinuz"
INITRAMFS="$ROOTFS_DIR/kubesolo-os.gz"
GRUB_CFG="$PROJECT_ROOT/build/grub/grub.cfg"
GRUB_ENV_DEFAULTS="$PROJECT_ROOT/build/grub/grub-env-defaults"
for f in "$VMLINUZ" "$INITRAMFS" "$GRUB_CFG" "$GRUB_ENV_DEFAULTS"; do
[ -f "$f" ] || { echo "ERROR: Missing $f"; exit 1; }
done
echo "==> Creating ${IMG_SIZE_MB}MB disk image with A/B partitions..."
mkdir -p "$OUTPUT_DIR"
# Create sparse image
dd if=/dev/zero of="$IMG_OUTPUT" bs=1M count=0 seek="$IMG_SIZE_MB" 2>/dev/null
# Partition (GPT):
# Part 1: 256 MB EFI System Partition (FAT32)
# Part 2: 512 MB System A (Linux filesystem)
# Part 3: 512 MB System B (Linux filesystem)
# Part 4: Remaining — Data (Linux filesystem)
sfdisk "$IMG_OUTPUT" << EOF
label: gpt
# EFI/Boot partition: 256 MB
start=2048, size=524288, type=C12A7328-F81F-11D2-BA4B-00A0C93EC93B, name="EFI"
# System A partition: 512 MB
size=1048576, type=0FC63DAF-8483-4772-8E79-3D69D8477DE4, name="SystemA"
# System B partition: 512 MB
size=1048576, type=0FC63DAF-8483-4772-8E79-3D69D8477DE4, name="SystemB"
# Data partition: remaining
type=0FC63DAF-8483-4772-8E79-3D69D8477DE4, name="Data"
EOF
# Set up loop device with partition mappings
LOOP=$(losetup --show -f "$IMG_OUTPUT")
echo "==> Loop device: $LOOP"
# Use kpartx for reliable partition device nodes (works in Docker/containers)
USE_KPARTX=false
if [ ! -b "${LOOP}p1" ]; then
if command -v kpartx >/dev/null 2>&1; then
kpartx -a "$LOOP"
USE_KPARTX=true
sleep 1
LOOP_NAME=$(basename "$LOOP")
P1="/dev/mapper/${LOOP_NAME}p1"
P2="/dev/mapper/${LOOP_NAME}p2"
P3="/dev/mapper/${LOOP_NAME}p3"
P4="/dev/mapper/${LOOP_NAME}p4"
else
# Retry with -P flag
losetup -d "$LOOP"
LOOP=$(losetup --show -fP "$IMG_OUTPUT")
sleep 1
P1="${LOOP}p1"
P2="${LOOP}p2"
P3="${LOOP}p3"
P4="${LOOP}p4"
fi
else
P1="${LOOP}p1"
P2="${LOOP}p2"
P3="${LOOP}p3"
P4="${LOOP}p4"
fi
MNT_EFI=$(mktemp -d)
MNT_SYSA=$(mktemp -d)
MNT_SYSB=$(mktemp -d)
MNT_DATA=$(mktemp -d)
cleanup() {
umount "$MNT_EFI" 2>/dev/null || true
umount "$MNT_SYSA" 2>/dev/null || true
umount "$MNT_SYSB" 2>/dev/null || true
umount "$MNT_DATA" 2>/dev/null || true
if [ "$USE_KPARTX" = true ]; then
kpartx -d "$LOOP" 2>/dev/null || true
fi
losetup -d "$LOOP" 2>/dev/null || true
rm -rf "$MNT_EFI" "$MNT_SYSA" "$MNT_SYSB" "$MNT_DATA" 2>/dev/null || true
}
trap cleanup EXIT
# Format partitions
mkfs.vfat -F 32 -n KSOLOEFI "$P1"
mkfs.ext4 -q -L KSOLOA "$P2"
mkfs.ext4 -q -L KSOLOB "$P3"
mkfs.ext4 -q -L KSOLODATA "$P4"
# Mount all partitions
mount "$P1" "$MNT_EFI"
mount "$P2" "$MNT_SYSA"
mount "$P3" "$MNT_SYSB"
mount "$P4" "$MNT_DATA"
# --- EFI/Boot Partition ---
echo " Installing GRUB..."
mkdir -p "$MNT_EFI/EFI/BOOT"
mkdir -p "$MNT_EFI/boot/grub"
# Copy GRUB config
cp "$GRUB_CFG" "$MNT_EFI/boot/grub/grub.cfg"
# Create GRUB environment file from defaults
if command -v grub-editenv >/dev/null 2>&1; then
GRUB_EDITENV=grub-editenv
elif command -v grub2-editenv >/dev/null 2>&1; then
GRUB_EDITENV=grub2-editenv
else
GRUB_EDITENV=""
fi
GRUBENV_FILE="$MNT_EFI/boot/grub/grubenv"
if [ -n "$GRUB_EDITENV" ]; then
# Create grubenv with defaults
"$GRUB_EDITENV" "$GRUBENV_FILE" create
while IFS='=' read -r key value; do
# Skip comments and empty lines
case "$key" in
'#'*|'') continue ;;
esac
"$GRUB_EDITENV" "$GRUBENV_FILE" set "$key=$value"
done < "$GRUB_ENV_DEFAULTS"
echo " GRUB environment created with grub-editenv"
else
# Fallback: write grubenv file manually (1024 bytes, padded with '#')
echo " WARN: grub-editenv not found — writing grubenv manually"
{
echo "# GRUB Environment Block"
while IFS='=' read -r key value; do
case "$key" in
'#'*|'') continue ;;
esac
echo "$key=$value"
done < "$GRUB_ENV_DEFAULTS"
} > "$GRUBENV_FILE.tmp"
# Pad to 1024 bytes (GRUB requirement)
truncate -s 1024 "$GRUBENV_FILE.tmp"
mv "$GRUBENV_FILE.tmp" "$GRUBENV_FILE"
fi
# Install GRUB EFI binary if available
if command -v grub-mkimage >/dev/null 2>&1; then
grub-mkimage -O x86_64-efi -o "$MNT_EFI/EFI/BOOT/bootx64.efi" \
-p /boot/grub \
part_gpt ext2 fat normal linux echo all_video test search \
search_fs_uuid search_label configfile loadenv \
2>/dev/null || echo " WARN: grub-mkimage failed — use QEMU -bios flag"
elif command -v grub2-mkimage >/dev/null 2>&1; then
grub2-mkimage -O x86_64-efi -o "$MNT_EFI/EFI/BOOT/bootx64.efi" \
-p /boot/grub \
part_gpt ext2 fat normal linux echo all_video test search \
search_fs_uuid search_label configfile loadenv \
2>/dev/null || echo " WARN: grub2-mkimage failed — use QEMU -bios flag"
else
echo " WARN: grub-mkimage not found — EFI boot image not created"
echo " Install grub2-tools or use QEMU -kernel/-initrd flags"
fi
# For BIOS boot: install GRUB i386-pc modules if available
if command -v grub-install >/dev/null 2>&1; then
grub-install --target=i386-pc --boot-directory="$MNT_EFI/boot" \
--no-floppy "$LOOP" 2>/dev/null || {
echo " WARN: BIOS GRUB install failed — EFI-only or use QEMU -kernel"
}
elif command -v grub2-install >/dev/null 2>&1; then
grub2-install --target=i386-pc --boot-directory="$MNT_EFI/boot" \
--no-floppy "$LOOP" 2>/dev/null || {
echo " WARN: BIOS GRUB install failed — EFI-only or use QEMU -kernel"
}
fi
# --- System A Partition (active) ---
echo " Populating System A (active)..."
cp "$VMLINUZ" "$MNT_SYSA/vmlinuz"
cp "$INITRAMFS" "$MNT_SYSA/kubesolo-os.gz"
echo "$VERSION" > "$MNT_SYSA/version"
# --- System B Partition (passive, initially same as A) ---
echo " Populating System B (passive)..."
cp "$VMLINUZ" "$MNT_SYSB/vmlinuz"
cp "$INITRAMFS" "$MNT_SYSB/kubesolo-os.gz"
echo "$VERSION" > "$MNT_SYSB/version"
# --- Data Partition ---
echo " Preparing data partition..."
for dir in kubesolo containerd etc-kubesolo log usr-local network images; do
mkdir -p "$MNT_DATA/$dir"
done
sync
echo ""
echo "==> Disk image created: $IMG_OUTPUT"
echo " Size: $(du -h "$IMG_OUTPUT" | cut -f1)"
echo " Part 1 (KSOLOEFI): GRUB + A/B boot config"
echo " Part 2 (KSOLOA): System A — kernel + initramfs (active)"
echo " Part 3 (KSOLOB): System B — kernel + initramfs (passive)"
echo " Part 4 (KSOLODATA): Persistent K8s state"
echo ""