fix: installer auto-start via profile.d, revert to embedded EFI, dark ISOLINUX

Three fixes from real hardware testing:

1. Installer auto-start: replace systemd service with profile.d script.
   The service and getty raced on tty1 — service output was overwritten
   by the login prompt. Profile.d runs AFTER auto-login, same approach
   the working Debian Live build used.

2. xorriso: revert from -append_partition to embedded -e boot/grub/efi.img.
   The appended partition approach produces cyl-align-off with zero CHS
   geometry, which is why BIOS wouldn't recognize the USB. The embedded
   approach matches the working main ISO (cyl-align-on, proper CHS).

3. ISOLINUX: dark theme instead of ugly blue. Black background, orange
   title, dark selection highlight. No blue boxes.

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

image-recipe/build-auto-installer-iso.sh

@@ -505,33 +505,18 @@ ExecStart=
 ExecStart=-/sbin/agetty --autologin root --noclear %I \$TERM
 GETTY
 
-# Create the installer auto-start systemd service
+# Auto-start installer via profile.d (runs after auto-login, no getty race)
-cat > /installer/etc/systemd/system/archipelago-installer.service <<SVCFILE
+# This is the same approach the working Debian Live build used.
-[Unit]
+mkdir -p /installer/etc/profile.d
-Description=Archipelago Auto-Installer
+cat > /installer/etc/profile.d/z99-archipelago-installer.sh <<PROFILE
-After=multi-user.target systemd-logind.service
-Wants=multi-user.target
-
-[Service]
-Type=oneshot
-ExecStart=/usr/local/bin/archipelago-start-installer
-StandardInput=tty
-StandardOutput=tty
-StandardError=tty
-TTYPath=/dev/tty1
-TTYReset=yes
-TTYVHangup=yes
-RemainAfterExit=yes
-
-[Install]
-WantedBy=multi-user.target
-SVCFILE
-chroot /installer systemctl enable archipelago-installer.service
-
-# Create the installer start wrapper
-cat > /installer/usr/local/bin/archipelago-start-installer <<WRAPPER
 #!/bin/bash
-sleep 2
+# Auto-start Archipelago installer on login — only run once
+if [ -n "\$INSTALLER_STARTED" ]; then
+    return 0 2>/dev/null || exit 0
+fi
+export INSTALLER_STARTED=1
+
+sleep 1
 clear
 echo ""
 echo "  ARCHIPELAGO BITCOIN NODE OS"
@@ -551,16 +536,17 @@ if [ -n "\$BOOT_MEDIA" ]; then
     echo ""
     echo "  Press Enter to start installation, or Ctrl+C for shell..."
     read
-    exec bash "\$BOOT_MEDIA/archipelago/auto-install.sh"
+    sudo bash "\$BOOT_MEDIA/archipelago/auto-install.sh"
 else
     echo "  Installer not found on boot media."
     echo "  Checked: /run/live/medium, /run/archiso, /cdrom, /media/cdrom"
     echo ""
-    echo "  Dropping to shell for manual recovery..."
+    echo "  You can try manually:"
-    exec /bin/bash
+    echo "    sudo bash /path/to/archipelago/auto-install.sh"
+    echo ""
 fi
-WRAPPER
+PROFILE
-chmod +x /installer/usr/local/bin/archipelago-start-installer
+chmod +x /installer/etc/profile.d/z99-archipelago-installer.sh
 
 # Custom initramfs hook: mount ISO boot media at /run/archiso
 mkdir -p /installer/etc/initramfs-tools/hooks
@@ -692,7 +678,7 @@ cp "$WORK_DIR/vmlinuz" "$INSTALLER_ISO/live/vmlinuz"
 cp "$WORK_DIR/initrd.img" "$INSTALLER_ISO/live/initrd.img"
 cp "$WORK_DIR/filesystem.squashfs" "$INSTALLER_ISO/live/filesystem.squashfs"
 cp "$WORK_DIR/BOOTX64.EFI" "$INSTALLER_ISO/EFI/BOOT/BOOTX64.EFI"
-# Note: efi.img stays in $WORK_DIR — it gets appended as GPT partition 2 by xorriso
+cp "$WORK_DIR/efi.img" "$INSTALLER_ISO/boot/grub/efi.img"
 cp "$WORK_DIR/isolinux.bin" "$INSTALLER_ISO/isolinux/isolinux.bin"
 cp "$WORK_DIR/ldlinux.c32" "$INSTALLER_ISO/isolinux/ldlinux.c32"
 cp "$WORK_DIR/menu.c32" "$INSTALLER_ISO/isolinux/menu.c32" 2>/dev/null || true
@@ -2572,11 +2558,17 @@ UI menu.c32
 PROMPT 0
 TIMEOUT 50
 
-MENU TITLE ARCHIPELAGO INSTALLER
+MENU TITLE ARCHIPELAGO - Bitcoin Node OS
-MENU COLOR border       30;44   #40ffffff #00000000 std
+MENU COLOR screen      37;40   #80ffffff #00000000 std
-MENU COLOR title        1;36;44 #ff00b7ff #00000000 std
+MENU COLOR border      30;40   #00000000 #00000000 none
-MENU COLOR sel          7;37;40 #ffffffff #ff333333 std
+MENU COLOR title       1;37;40 #fffb923c #00000000 std
-MENU COLOR unsel        37;44   #ffaaaaaa #00000000 std
+MENU COLOR sel         7;37;40 #ffffffff #ff1a1a1a std
+MENU COLOR unsel       37;40   #ff999999 #00000000 std
+MENU COLOR hotkey      1;37;40 #fffb923c #00000000 std
+MENU COLOR hotsel      1;37;40 #fffb923c #ff1a1a1a std
+MENU COLOR timeout_msg 37;40   #ff666666 #00000000 std
+MENU COLOR timeout     1;37;40 #fffb923c #00000000 std
+MENU COLOR tabmsg      37;40   #ff666666 #00000000 std
 
 DEFAULT install
 
@@ -2631,44 +2623,36 @@ if [ ! -f "$ISOHDPFX" ]; then
     done
 fi
 
-# EFI boot image was built in Step 2 and placed at staging/efiboot.img
+# EFI boot image — embedded inside ISO (same approach as the working main ISO)
-# The Will Haley / Debian live-build approach: append EFI as GPT partition 2
+# The efi.img must be copied into the ISO directory in Step 2 artifact placement
-# This is what makes USB boot work on real UEFI hardware (not just QEMU)
+EFI_IMG="$INSTALLER_ISO/boot/grub/efi.img"
-EFIBOOT="$WORK_DIR/efi.img"
 
-if [ ! -f "$EFIBOOT" ]; then
+if [ ! -f "$EFI_IMG" ]; then
     echo "   WARNING: No EFI boot image — ISO will only support Legacy BIOS boot"
     xorriso -as mkisofs -o "$OUTPUT_ISO" \
         -volid "ARCHIPELAGO" \
         -iso-level 3 \
-        -full-iso9660-filenames \
+        -J -joliet-long -R \
-        --mbr-force-bootable -partition_offset 16 \
-        -joliet -joliet-long -rational-rock \
         -isohybrid-mbr "$ISOHDPFX" \
-        -eltorito-boot isolinux/isolinux.bin \
+        -c isolinux/boot.cat \
-            -no-emul-boot \
+        -b isolinux/isolinux.bin \
-            -boot-load-size 4 \
+        -no-emul-boot -boot-load-size 4 -boot-info-table \
-            -boot-info-table \
+        -partition_offset 16 \
-            --eltorito-catalog isolinux/isolinux.cat \
         "$INSTALLER_ISO"
 else
     xorriso -as mkisofs -o "$OUTPUT_ISO" \
         -volid "ARCHIPELAGO" \
         -iso-level 3 \
-        -full-iso9660-filenames \
+        -J -joliet-long -R \
-        --mbr-force-bootable -partition_offset 16 \
-        -joliet -joliet-long -rational-rock \
         -isohybrid-mbr "$ISOHDPFX" \
-        -eltorito-boot isolinux/isolinux.bin \
+        -c isolinux/boot.cat \
-            -no-emul-boot \
+        -b isolinux/isolinux.bin \
-            -boot-load-size 4 \
+        -no-emul-boot -boot-load-size 4 -boot-info-table \
-            -boot-info-table \
-            --eltorito-catalog isolinux/isolinux.cat \
         -eltorito-alt-boot \
-            -e --interval:appended_partition_2:all:: \
+        -e boot/grub/efi.img \
-            -no-emul-boot \
+        -no-emul-boot \
-            -isohybrid-gpt-basdat \
+        -isohybrid-gpt-basdat \
-        -append_partition 2 C12A7328-F81F-11D2-BA4B-00A0C93EC93B "$EFIBOOT" \
+        -partition_offset 16 \
         "$INSTALLER_ISO"
 fi