fix(iso): clear stale bootloader templates in workdir

iso/builder/build.sh

@@ -126,6 +126,37 @@ resolve_iso_version() {
     resolve_audit_version
 }
 
+sync_builder_workdir() {
+    src_dir="$1"
+    dst_dir="$2"
+
+    mkdir -p "$dst_dir"
+
+    # Historical bug: old workdirs could keep config/bootloaders/grub-pc even
+    # after the source tree moved to grub-efi only. Remove bootloaders eagerly
+    # so reused workdirs cannot leak stale templates into a new ISO build.
+    rm -rf "$dst_dir/config/bootloaders"
+
+    rsync -a --delete \
+        --exclude='cache/' \
+        --exclude='chroot/' \
+        --exclude='.build/' \
+        --exclude='*.iso' \
+        --exclude='*.packages' \
+        --exclude='*.contents' \
+        --exclude='*.files' \
+        "$src_dir/" "$dst_dir/"
+
+    if [ ! -f "$dst_dir/config/bootloaders/grub-efi/grub.cfg" ]; then
+        echo "ERROR: staged workdir is missing config/bootloaders/grub-efi/grub.cfg" >&2
+        exit 1
+    fi
+    if [ -e "$dst_dir/config/bootloaders/grub-pc" ]; then
+        echo "ERROR: stale config/bootloaders/grub-pc remained in staged workdir" >&2
+        exit 1
+    fi
+}
+
 iso_list_files() {
     iso_path="$1"
 
@@ -466,6 +497,75 @@ validate_iso_memtest() {
     echo "=== memtest validation OK ==="
 }
 
+validate_iso_live_boot_entries() {
+    iso_path="$1"
+    echo "=== validating live boot entries in ISO ==="
+
+    [ -f "$iso_path" ] || {
+        echo "ERROR: ISO not found for live boot validation: $iso_path" >&2
+        exit 1
+    }
+    require_iso_reader "$iso_path" >/dev/null 2>&1 || {
+        echo "ERROR: ISO reader unavailable for live boot validation" >&2
+        exit 1
+    }
+
+    grub_cfg="$(mktemp)"
+    isolinux_cfg="$(mktemp)"
+
+    iso_read_member "$iso_path" boot/grub/grub.cfg "$grub_cfg" || {
+        echo "ERROR: failed to read boot/grub/grub.cfg from ISO" >&2
+        rm -f "$grub_cfg" "$isolinux_cfg"
+        exit 1
+    }
+    iso_read_member "$iso_path" isolinux/live.cfg "$isolinux_cfg" || {
+        echo "ERROR: failed to read isolinux/live.cfg from ISO" >&2
+        rm -f "$grub_cfg" "$isolinux_cfg"
+        exit 1
+    }
+
+    if grep -q '@APPEND_LIVE@\|@KERNEL_LIVE@\|@INITRD_LIVE@' "$grub_cfg" "$isolinux_cfg"; then
+        echo "ERROR: unresolved live-build placeholders remain in ISO bootloader config" >&2
+        rm -f "$grub_cfg" "$isolinux_cfg"
+        exit 1
+    fi
+
+    grep -q 'menuentry "EASY-BEE"' "$grub_cfg" || {
+        echo "ERROR: GRUB default EASY-BEE entry is missing" >&2
+        rm -f "$grub_cfg" "$isolinux_cfg"
+        exit 1
+    }
+    grep -q 'menuentry "EASY-BEE — load to RAM (toram)"' "$grub_cfg" || {
+        echo "ERROR: GRUB toram entry is missing" >&2
+        rm -f "$grub_cfg" "$isolinux_cfg"
+        exit 1
+    }
+    grep -q 'linux .*boot=live ' "$grub_cfg" || {
+        echo "ERROR: GRUB live entry is missing boot=live" >&2
+        rm -f "$grub_cfg" "$isolinux_cfg"
+        exit 1
+    }
+    grep -q 'linux .*boot=live .*toram ' "$grub_cfg" || {
+        echo "ERROR: GRUB toram entry is missing boot=live or toram" >&2
+        rm -f "$grub_cfg" "$isolinux_cfg"
+        exit 1
+    }
+
+    grep -q 'append .*boot=live ' "$isolinux_cfg" || {
+        echo "ERROR: isolinux live entry is missing boot=live" >&2
+        rm -f "$grub_cfg" "$isolinux_cfg"
+        exit 1
+    }
+    grep -q 'append .*boot=live .*toram ' "$isolinux_cfg" || {
+        echo "ERROR: isolinux toram entry is missing boot=live or toram" >&2
+        rm -f "$grub_cfg" "$isolinux_cfg"
+        exit 1
+    }
+
+    rm -f "$grub_cfg" "$isolinux_cfg"
+    echo "=== live boot validation OK ==="
+}
+
 validate_iso_nvidia_runtime() {
     iso_path="$1"
     [ "$BEE_GPU_VENDOR" = "nvidia" ] || return 0
@@ -1112,15 +1212,7 @@ echo "=== preparing staged overlay (${BUILD_VARIANT}) ==="
 mkdir -p "${BUILD_WORK_DIR}" "${OVERLAY_STAGE_DIR}"
 
 # Sync builder config into variant work dir, preserving lb cache.
-rsync -a --delete \
+sync_builder_workdir "${BUILDER_DIR}" "${BUILD_WORK_DIR}"
-    --exclude='cache/' \
-    --exclude='chroot/' \
-    --exclude='.build/' \
-    --exclude='*.iso' \
-    --exclude='*.packages' \
-    --exclude='*.contents' \
-    --exclude='*.files' \
-    "${BUILDER_DIR}/" "${BUILD_WORK_DIR}/"
 
 # Share deb package cache across variants.
 # Restore: populate work dir cache from shared cache before build.
@@ -1441,6 +1533,7 @@ if [ -f "$ISO_RAW" ]; then
         fi
     fi
     validate_iso_memtest "$ISO_RAW"
+    validate_iso_live_boot_entries "$ISO_RAW"
     validate_iso_nvidia_runtime "$ISO_RAW"
     cp "$ISO_RAW" "$ISO_OUT"
     echo ""