The NVIDIA GSP firmware was staged into the overlay at a bare
lib/firmware/nvidia/<ver>/. On a merged-usr Debian root /lib is a symlink
to usr/lib, so the fast-path repack's `rsync -a` (overlay stage -> the
unsquashfs'd tree) replaced that symlink with a plain directory holding
only the firmware. Everything else reachable only through /lib
(/lib/systemd/systemd, /lib/x86_64-linux-gnu/ld-linux + libc, ...) was
orphaned. The squashfs still packed and mounted, but boot panicked:
run-init: can't execute '/sbin/init': No such file or directory
run-init: can't execute '/bin/sh': No such file or directory
Kernel panic - not syncing: Attempted to kill init
Full `lb build` was unaffected (live-build copies includes.chroot with
cp -a, which follows the /lib symlink), so only fast-path ISOs were bad.
Three fixes:
- build.sh: stage GSP firmware under usr/lib/firmware/nvidia/<ver>/, the
canonical merged-usr path. Changing the overlay path also makes
overlay_paths_were_removed() force one full build on the next run.
- fast-path.sh: add `rsync --keep-dirlinks` so a real directory in the
overlay stage can never again replace a symlink-to-directory in the
root. Verified: firmware lands in usr/lib/firmware, /lib stays a symlink.
- iso-validation.sh: new validate_iso_rootfs_layout, run for every variant
on both build paths. Fails the build if the squashfs has a plain-dir
/bin|/sbin|/lib|/lib64, or if /usr/sbin/init is present without a
resolvable /usr/lib/systemd/systemd and /lib symlink. Verified it flags
the broken v14.02-1-g642e686 ISO and passes a correct layout.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01H2LLuid8PFhBqBPcxXxkQU
needs_full_build() decided the fast path was safe by hashing only config
inputs (VERSIONS, package lists, hooks, archives, auto/config, Dockerfile).
It never hashed the build logic itself, so a change to build.sh or
lib/fast-path.sh counted as a "light" file and the next build silently
reused a squashfs produced by the old code. The merged-usr /lib fix in the
previous commit only forced a full rebuild by accident (the overlay
manifest saw firmware move from lib/ to usr/lib/).
hash_heavy_config now covers every *.sh under iso/builder (build.sh, the
build-*.sh helpers, lib/*.sh) plus auto/. A change to build logic is now
as heavy as a package-list change. config/bootloaders stays excluded (the
fast path regenerates the outer ISO layer from it every time). Hash is
deterministic (LC_ALL=C sort).
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01H2LLuid8PFhBqBPcxXxkQU
