archy/image-recipe/create-usb-simple.sh
Dorian 8f0b080e73 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.
2026-01-31 23:37:56 +00:00

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#!/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 ""