fix(deploy): multi-model ISO builds and HAL packaging
- Parameterize live.nix by machineModel (douro/tejo) passed via specialArgs - Douro: kernel 5.15 LTS for Bay Trail i915 eDP fix, vt.handoff=7 - Fix HAL packaging: copy dist/ into subdirectory (not flattened) - Add display-reset systemd service for kexec GPU reinitialization - Add --disable-gpu flag for Electron on headless/GPU-less boots - flake.nix: mkLiveConfig helper, per-model ISO outputs (iso-douro/iso-tejo) - build-iso.sh: require model param, write model-specific .env for Vite - flash-douro-usb.sh: GPT+FAT32 ESP layout for Bay Trail UEFI boot Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
This commit is contained in:
Patrick Mulligan
parent
2605c44ef8
commit
c874d9e2e3
4 changed files with 325 additions and 31 deletions
195
deploy/nixos/flash-douro-usb.sh
Executable file
195
deploy/nixos/flash-douro-usb.sh
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#!/usr/bin/env bash
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# Flash a NixOS Live ISO to a USB stick with a proper GPT + FAT32 ESP layout.
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#
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# Bay Trail (Douro) UEFI firmware can't boot from raw dd'd ISOs because it
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# doesn't parse the El Torito EFI boot catalog embedded in ISO9660. This script
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# creates a standard GPT partition with a FAT32 filesystem containing the
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# EFI bootloader, kernel, initrd, and NixOS squashfs — which Bay Trail
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# firmware recognizes natively.
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#
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# Usage: sudo bash flash-usb.sh /dev/sdX [path/to/iso]
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#
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# If no ISO path is given, uses the most recent build in result/iso/.
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set -euo pipefail
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USB_DEV="${1:-}"
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ISO_PATH="${2:-}"
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if [ -z "$USB_DEV" ]; then
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echo "Usage: sudo bash flash-usb.sh /dev/sdX [path/to/iso]"
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echo ""
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echo " /dev/sdX USB device (NOT a partition — e.g. /dev/sdc, not /dev/sdc1)"
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echo " path/to/iso Optional ISO path (default: result/iso/*.iso)"
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echo ""
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echo "WARNING: This will erase ALL data on the target device!"
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exit 1
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fi
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# Safety checks
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if [ "$(id -u)" -ne 0 ]; then
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echo "ERROR: Must run as root (sudo)"
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exit 1
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fi
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if [ ! -b "$USB_DEV" ]; then
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echo "ERROR: $USB_DEV is not a block device"
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exit 1
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fi
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# Don't accidentally wipe a hard drive
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if echo "$USB_DEV" | grep -qE '^/dev/(sda|nvme|vda)'; then
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echo "ERROR: $USB_DEV looks like a system drive. Refusing to proceed."
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echo " Use a removable USB device (e.g. /dev/sdb, /dev/sdc)."
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exit 1
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fi
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# Find ISO
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SCRIPT_DIR="$(cd "$(dirname "${BASH_SOURCE[0]}")" && pwd)"
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if [ -z "$ISO_PATH" ]; then
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ISO_PATH=$(ls "$SCRIPT_DIR"/result/iso/*.iso 2>/dev/null | head -1)
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if [ -z "$ISO_PATH" ]; then
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echo "ERROR: No ISO found in $SCRIPT_DIR/result/iso/"
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echo " Build one first: bash build-iso.sh douro"
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exit 1
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fi
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fi
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if [ ! -f "$ISO_PATH" ]; then
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echo "ERROR: ISO not found: $ISO_PATH"
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exit 1
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fi
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ISO_SIZE=$(du -h "$ISO_PATH" | cut -f1)
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USB_SIZE=$(lsblk -dno SIZE "$USB_DEV" 2>/dev/null || echo "unknown")
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USB_MODEL=$(lsblk -dno MODEL "$USB_DEV" 2>/dev/null || echo "unknown")
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echo "=== Flash NixOS Live USB ==="
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echo "ISO: $ISO_PATH ($ISO_SIZE)"
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echo "Target: $USB_DEV ($USB_SIZE, $USB_MODEL)"
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echo ""
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echo "WARNING: ALL data on $USB_DEV will be destroyed!"
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read -p "Continue? (y/N) " -r
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if [[ ! "$REPLY" =~ ^[Yy]$ ]]; then
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echo "Aborted."
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exit 0
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fi
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# Unmount any mounted partitions on the USB
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echo ""
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echo "--- Unmounting existing partitions ---"
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for part in "${USB_DEV}"*; do
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if mountpoint -q "$part" 2>/dev/null || mount | grep -q "^$part "; then
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umount "$part" 2>/dev/null || true
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echo "Unmounted $part"
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fi
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done
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# Step 1: Create GPT partition table with a single FAT32 partition
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echo ""
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echo "--- Step 1: Creating GPT partition table ---"
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parted -s "$USB_DEV" mklabel gpt
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parted -s "$USB_DEV" mkpart ESP fat32 1MiB 100%
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parted -s "$USB_DEV" set 1 esp on
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echo "OK: GPT with ESP partition"
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# Wait for kernel to pick up new partition table
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sleep 2
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partprobe "$USB_DEV" 2>/dev/null || true
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sleep 1
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# Find the partition device (handles both /dev/sdc1 and /dev/nvme0n1p1 styles)
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PART_DEV="${USB_DEV}1"
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if [ ! -b "$PART_DEV" ]; then
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PART_DEV="${USB_DEV}p1"
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fi
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if [ ! -b "$PART_DEV" ]; then
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echo "ERROR: Partition device not found (tried ${USB_DEV}1 and ${USB_DEV}p1)"
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exit 1
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fi
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# Step 2: Format as FAT32
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# FAT32 volume labels are max 11 chars, so we use a short label.
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# The kernel finds root by LABEL=nixos-24.05-x86_64 which is on the ISO9660.
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# But since we're extracting the ISO, we set the label on the FAT32 partition.
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# NixOS initrd also searches by /nix-store.squashfs file presence.
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echo ""
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echo "--- Step 2: Formatting FAT32 ---"
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mkfs.fat -F32 -n 'NIXOS2405' "$PART_DEV"
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echo "OK: FAT32 formatted"
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# Step 3: Mount ISO and USB partition
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echo ""
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echo "--- Step 3: Mounting ISO and USB ---"
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MNT_ISO=$(mktemp -d)
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MNT_USB=$(mktemp -d)
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mount -o loop,ro "$ISO_PATH" "$MNT_ISO"
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mount "$PART_DEV" "$MNT_USB"
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echo "ISO mounted at $MNT_ISO"
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echo "USB mounted at $MNT_USB"
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# Cleanup function
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cleanup() {
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echo ""
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echo "--- Cleaning up ---"
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umount "$MNT_USB" 2>/dev/null || true
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umount "$MNT_ISO" 2>/dev/null || true
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rmdir "$MNT_ISO" 2>/dev/null || true
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rmdir "$MNT_USB" 2>/dev/null || true
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}
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trap cleanup EXIT
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# Step 4: Copy EFI boot files (UPPERCASE paths for Bay Trail UEFI compatibility)
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echo ""
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echo "--- Step 4: Copying EFI boot files ---"
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mkdir -p "$MNT_USB/EFI/BOOT"
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cp "$MNT_ISO/EFI/boot/bootx64.efi" "$MNT_USB/EFI/BOOT/BOOTX64.EFI"
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cp "$MNT_ISO/EFI/boot/grub.cfg" "$MNT_USB/EFI/BOOT/grub.cfg"
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cp -r "$MNT_ISO/EFI/boot/grub-theme" "$MNT_USB/EFI/BOOT/grub-theme"
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cp "$MNT_ISO/EFI/boot/unicode.pf2" "$MNT_USB/EFI/BOOT/unicode.pf2"
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cp "$MNT_ISO/EFI/boot/efi-background.png" "$MNT_USB/EFI/BOOT/efi-background.png"
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if [ -f "$MNT_ISO/EFI/boot/refind_x64.efi" ]; then
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cp "$MNT_ISO/EFI/boot/refind_x64.efi" "$MNT_USB/EFI/BOOT/refind_x64.efi"
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fi
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# Create the marker file GRUB searches for (search --file /EFI/nixos-installer-image)
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mkdir -p "$MNT_USB/EFI"
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touch "$MNT_USB/EFI/nixos-installer-image"
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echo "OK: EFI boot files copied"
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# Step 5: Copy boot directory (kernel, initrd, grub modules)
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echo ""
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echo "--- Step 5: Copying kernel and initrd ---"
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cp -r "$MNT_ISO/boot" "$MNT_USB/boot"
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echo "OK: Kernel and initrd copied"
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# Step 6: Fix GRUB config paths (lowercase -> uppercase for our layout)
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echo ""
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echo "--- Step 6: Fixing GRUB config paths ---"
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sed -i 's|/EFI/boot/|/EFI/BOOT/|g' "$MNT_USB/EFI/BOOT/grub.cfg"
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echo "OK: GRUB paths updated"
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# Step 7: Copy NixOS root filesystem (this is the big one ~2GB)
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echo ""
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echo "--- Step 7: Copying NixOS squashfs (this takes a while) ---"
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cp "$MNT_ISO/nix-store.squashfs" "$MNT_USB/nix-store.squashfs"
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if [ -f "$MNT_ISO/version.txt" ]; then
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cp "$MNT_ISO/version.txt" "$MNT_USB/version.txt"
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fi
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echo "OK: squashfs copied"
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# Step 8: Sync
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echo ""
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echo "--- Step 8: Syncing to disk ---"
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sync
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echo "OK: All data written"
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# Cleanup happens via trap
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echo ""
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echo "=== USB flash complete ==="
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echo "Device: $USB_DEV"
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echo ""
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echo "Now plug it into the target machine and boot from USB."
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echo "The GRUB menu should appear with NixOS installer options."
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echo ""
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echo "After booting, provision credentials with:"
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echo " bash provision-atm.sh <atm-ip> 22"
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