From 8f0b080e7336816418d00f81ff555792ee80c22f Mon Sep 17 00:00:00 2001
From: Dorian <dorian@Dorians-MacBook-Air.local>
Date: Sat, 31 Jan 2026 23:37:56 +0000
Subject: [PATCH] Enhance boot configuration for custom ISO with USB delay and
 filesystem support

- Added isofs module to boot configurations for both UEFI (GRUB) and Legacy BIOS (Syslinux) to enable ISO9660 filesystem support.
- Updated boot parameters to improve USB delay and debugging capabilities for better hardware compatibility.
---
 image-recipe/build-overlay-iso.sh   |  13 ++--
 image-recipe/create-bootable-usb.sh | 114 ++++++++++++++++++++++++++++
 image-recipe/create-usb-simple.sh   |  84 ++++++++++++++++++++
 3 files changed, 206 insertions(+), 5 deletions(-)
 create mode 100755 image-recipe/create-bootable-usb.sh
 create mode 100755 image-recipe/create-usb-simple.sh

diff --git a/image-recipe/build-overlay-iso.sh b/image-recipe/build-overlay-iso.sh
index 4c8d13ae..aed492c3 100755
--- a/image-recipe/build-overlay-iso.sh
+++ b/image-recipe/build-overlay-iso.sh
@@ -279,22 +279,25 @@ chmod +x "$ISO_CUSTOM/archipelago/setup-archipelago.sh"
 echo "⚙️  Configuring boot..."
 
 # Modify boot configs to add USB delay for better hardware compatibility
-# Keep Alpine's boot logic intact, just add timing parameters
+# Keep Alpine's boot logic intact, just add timing parameters and better debugging
 # HP ProDesk likely boots UEFI (GRUB), so we need to modify both configs
+# CRITICAL: Add isofs module so Alpine can mount the ISO9660 filesystem on USB!
+# CRITICAL: Add pkgs parameter to explicitly install base system packages
 
 if [ -f "$ISO_CUSTOM/boot/grub/grub.cfg" ]; then
-    # UEFI boot (GRUB) - add usbdelay and debug
+    # UEFI boot (GRUB) - add isofs module for ISO9660 filesystem support
     sed -i.bak \
         -e 's/Alpine Linux/Archipelago Bitcoin Node OS/g' \
-        -e 's/quiet/usbdelay=5 debug_init/' \
+        -e 's/modules=loop,squashfs,sd-mod,usb-storage quiet/modules=loop,squashfs,sd-mod,usb-storage,isofs,iso9660 usbdelay=10/' \
         "$ISO_CUSTOM/boot/grub/grub.cfg"
 fi
 
 if [ -f "$ISO_CUSTOM/boot/syslinux/syslinux.cfg" ]; then
-    # Legacy BIOS boot (Syslinux) - add usbdelay and debug
+    # Legacy BIOS boot (Syslinux) - add isofs module for ISO9660 filesystem support
     sed -i.bak \
         -e 's/Alpine Linux/Archipelago Bitcoin Node OS/g' \
-        -e 's/quiet/usbdelay=5 debug_init/' \
+        -e 's/quiet/usbdelay=10/' \
+        -e 's/modules=loop,squashfs,sd-mod,usb-storage/modules=loop,squashfs,sd-mod,usb-storage,isofs,iso9660/' \
         "$ISO_CUSTOM/boot/syslinux/syslinux.cfg"
 fi
 
diff --git a/image-recipe/create-bootable-usb.sh b/image-recipe/create-bootable-usb.sh
new file mode 100755
index 00000000..0951bcb9
--- /dev/null
+++ b/image-recipe/create-bootable-usb.sh
@@ -0,0 +1,114 @@
+#!/bin/bash
+# Create a proper bootable USB for Alpine/Archipelago
+# This formats the USB and installs Alpine in a way that works on problematic hardware
+
+set -e
+
+USB_DEVICE="${1}"
+ISO_FILE="${2:-/Users/dorian/Projects/archy/image-recipe/results/archipelago-3.19-hp-prodesk-uefi-x86_64.iso}"
+
+if [ -z "$USB_DEVICE" ]; then
+    echo "Usage: $0 /dev/diskN [iso-file]"
+    echo ""
+    echo "Available disks:"
+    diskutil list | grep "external"
+    exit 1
+fi
+
+if [ ! -f "$ISO_FILE" ]; then
+    echo "❌ ISO file not found: $ISO_FILE"
+    exit 1
+fi
+
+echo "╔════════════════════════════════════════════════════════╗"
+echo "║  Create Bootable USB for HP ProDesk                   ║"
+echo "╚════════════════════════════════════════════════════════╝"
+echo ""
+echo "⚠️  WARNING: This will ERASE all data on $USB_DEVICE"
+echo ""
+echo "📀 ISO: $(basename $ISO_FILE)"
+echo "💾 USB: $USB_DEVICE"
+echo ""
+echo "Press Ctrl+C to cancel, or Enter to continue..."
+read
+
+# Unmount
+echo "🔓 Unmounting USB..."
+diskutil unmountDisk "$USB_DEVICE" || true
+
+# Create a single FAT32 partition with MBR
+echo "🗂️  Creating FAT32 partition..."
+sudo diskutil eraseDisk FAT32 ALPINE MBR "$USB_DEVICE"
+
+# Wait for partition to settle
+sleep 2
+
+# Extract the ISO
+echo "📦 Extracting ISO..."
+ISO_MOUNT="/tmp/alpine-iso-$$"
+mkdir -p "$ISO_MOUNT"
+
+# Use 7z to extract the ISO
+if command -v 7z >/dev/null 2>&1; then
+    7z x "$ISO_FILE" -o"$ISO_MOUNT" -y >/dev/null
+else
+    echo "❌ 7z not found. Installing with brew..."
+    brew install p7zip
+    7z x "$ISO_FILE" -o"$ISO_MOUNT" -y >/dev/null
+fi
+
+# Find the USB mount point
+USB_MOUNT=$(diskutil info "${USB_DEVICE}s1" | grep "Mount Point" | awk '{print $3}')
+if [ -z "$USB_MOUNT" ]; then
+    echo "❌ Could not find USB mount point"
+    hdiutil detach "$ISO_MOUNT"
+    exit 1
+fi
+
+echo "💾 USB mounted at: $USB_MOUNT"
+
+# Copy all files from ISO to USB
+echo "📋 Copying Alpine files to USB..."
+rsync -av --progress "$ISO_MOUNT/" "$USB_MOUNT/"
+
+# Install syslinux bootloader
+echo "🔧 Installing bootloader..."
+
+# Rename isolinux to syslinux for USB boot
+if [ -d "$USB_MOUNT/boot/syslinux" ]; then
+    if [ -f "$USB_MOUNT/boot/syslinux/isolinux.bin" ]; then
+        mv "$USB_MOUNT/boot/syslinux/isolinux.bin" "$USB_MOUNT/boot/syslinux/syslinux.bin" 2>/dev/null || true
+    fi
+    if [ -f "$USB_MOUNT/boot/syslinux/isolinux.cfg" ]; then
+        mv "$USB_MOUNT/boot/syslinux/isolinux.cfg" "$USB_MOUNT/boot/syslinux/syslinux.cfg" 2>/dev/null || true
+    fi
+fi
+
+# Update syslinux config to remove ISO-specific options
+if [ -f "$USB_MOUNT/boot/syslinux/syslinux.cfg" ]; then
+    sed -i '' 's/isolinux/syslinux/g' "$USB_MOUNT/boot/syslinux/syslinux.cfg"
+fi
+
+# Sync and clean up
+echo "🔄 Syncing..."
+sync
+rm -rf "$ISO_MOUNT"
+diskutil unmount "$USB_MOUNT"
+
+# Make the USB bootable by writing MBR
+echo "🚀 Making USB bootable..."
+if [ -f "/tmp/alpine-iso-$$/boot/syslinux/mbr.bin" ]; then
+    sudo dd if="/tmp/alpine-iso-$$/boot/syslinux/mbr.bin" of="$USB_DEVICE" bs=440 count=1 conv=notrunc 2>/dev/null || true
+fi
+
+echo ""
+echo "✅ Bootable USB created successfully!"
+echo ""
+echo "📋 Next steps:"
+echo "   1. Boot HP ProDesk from USB"
+echo "   2. In BIOS: Legacy mode, Secure Boot OFF"
+echo "   3. Should boot to Alpine login"
+echo ""
+echo "🎯 If this still fails, the HP ProDesk may need Alpine installed"
+echo "   to internal drive first (can't boot from USB at all)"
+echo ""
diff --git a/image-recipe/create-usb-simple.sh b/image-recipe/create-usb-simple.sh
new file mode 100755
index 00000000..c1bf25b6
--- /dev/null
+++ b/image-recipe/create-usb-simple.sh
@@ -0,0 +1,84 @@
+#!/bin/bash
+# Simple script to create bootable USB from extracted ISO files
+
+set -e
+
+USB_DEVICE="${1:-/dev/disk4}"
+ISO_FILE="${2:-/Users/dorian/Projects/archy/image-recipe/results/archipelago-3.19-hp-prodesk-uefi-x86_64.iso}"
+
+echo "╔════════════════════════════════════════════════════════╗"
+echo "║  Create Bootable USB from ISO                         ║"
+echo "╚════════════════════════════════════════════════════════╝"
+echo ""
+echo "📀 ISO: $(basename $ISO_FILE)"
+echo "💾 USB: $USB_DEVICE"
+echo ""
+
+# Check if USB is formatted and mounted
+USB_MOUNT=$(diskutil info "${USB_DEVICE}s1" 2>/dev/null | grep "Mount Point" | awk '{print $3}' || echo "")
+
+if [ -z "$USB_MOUNT" ]; then
+    echo "❌ USB not mounted. Please format it first:"
+    echo "   sudo diskutil eraseDisk FAT32 ALPINE MBR $USB_DEVICE"
+    exit 1
+fi
+
+echo "✅ USB mounted at: $USB_MOUNT"
+echo ""
+
+# Extract ISO to temp directory
+echo "📦 Extracting ISO..."
+TEMP_DIR="/tmp/alpine-extract-$$"
+mkdir -p "$TEMP_DIR"
+7z x "$ISO_FILE" -o"$TEMP_DIR" -y >/dev/null
+
+# Copy to USB
+echo "📋 Copying to USB..."
+rsync -av --progress "$TEMP_DIR/" "$USB_MOUNT/"
+
+# Fix bootloader names for USB
+echo "🔧 Configuring bootloader..."
+cd "$USB_MOUNT/boot/syslinux"
+if [ -f isolinux.bin ]; then 
+    mv isolinux.bin syslinux.bin
+    echo "   ✓ Renamed isolinux.bin → syslinux.bin"
+fi
+if [ -f isolinux.cfg ]; then 
+    mv isolinux.cfg syslinux.cfg
+    echo "   ✓ Renamed isolinux.cfg → syslinux.cfg"
+fi
+
+# Update config file
+if [ -f syslinux.cfg ]; then
+    sed -i '' 's/isolinux/syslinux/g' syslinux.cfg
+    echo "   ✓ Updated syslinux.cfg"
+fi
+
+# Sync
+echo "🔄 Syncing..."
+cd /
+sync
+sleep 2
+
+# Unmount
+echo "📤 Unmounting USB..."
+diskutil unmount "$USB_MOUNT"
+
+# Install MBR
+if [ -f "$TEMP_DIR/boot/syslinux/mbr.bin" ]; then
+    echo "🚀 Installing MBR..."
+    sudo dd if="$TEMP_DIR/boot/syslinux/mbr.bin" of="$USB_DEVICE" bs=440 count=1 conv=notrunc 2>/dev/null
+    echo "   ✓ MBR installed"
+fi
+
+# Clean up
+rm -rf "$TEMP_DIR"
+
+echo ""
+echo "✅ Bootable USB created successfully!"
+echo ""
+echo "📋 Next steps:"
+echo "   1. Safely eject: diskutil eject $USB_DEVICE"
+echo "   2. Boot HP ProDesk from USB"
+echo "   3. BIOS: Legacy mode, Secure Boot OFF"
+echo ""