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Is it a known working SD card at that capacity ?
A bit of searching for that particular error points to a file system error, you may have to run fsck on the SD card on a Linux system.
I doubt that it has anything to do with the size of the drive, more likely filesystem error on the SD card.
I do a google search for the text contained in the error.

I suspect your SSD is too big given the bugs in the volume sizing upstream. They never imagined people would use large volumes or build images as big as we need. I have not merged upstream changes which might fix it. I will try and do that.

If you want to add extra packages, the best method I found was to use Debian PAckage search packages.debian.org/index to locate your exact package and then add to this line
github.com/rodw-au/rpi-img-builder-lcnc/...ata.txt#L24C1-L24C11

Anything else needs to be done in  userscripts
github.com/rodw-au/rpi-img-builder-lcnc/...userscripts/uscripts
There are several section in  this file called at different times  but most of it is done in  run_function2 when the chroot exists
Files can be copied out of the chroot in run_function3  but the file paths change.
 

Hello guys, I continue experiments with just created image.
I have burned it on the SD Card 512Gb (not sure, probably it is to much?)
Did you faced with troubles like read-only root file system?
Here is what I have checked:

ago@pi-cnc:~$ sudo mount | grep /dev
udev on /dev type devtmpfs (rw,nosuid,relatime,size=1667364k,nr_inodes=416841,mode=755)
devpts on /dev/pts type devpts (rw,nosuid,noexec,relatime,gid=5,mode=620,ptmxmode=000)
/dev/mmcblk0p2 on / type ext4 (ro,noatime,errors=remount-ro,commit=600)
tmpfs on /dev/shm type tmpfs (rw,nosuid,nodev)
mqueue on /dev/mqueue type mqueue (rw,nosuid,nodev,noexec,relatime)
/dev/mmcblk0p1 on /boot/broadcom type vfat (rw,relatime,fmask=0022,dmask=0022,codepage=437,iocharset=ascii,shortname=mixed,flush,errors=remount-ro)

ago@pi-cnc:~$ sudo dmesg | grep mmcblk0p2
[    4.946191] EXT4-fs (mmcblk0p2): mounted filesystem with ordered data mode. Quota mode: none.
[    7.221878] EXT4-fs (mmcblk0p2): re-mounted. Quota mode: none.
[  216.642005] EXT4-fs error (device mmcblk0p2): ext4_validate_block_bitmap:420: comm http: bg 128: bad block bitmap checksum
[  216.642025] Aborting journal on device mmcblk0p2-8.
[  216.722933] EXT4-fs error (device mmcblk0p2): ext4_journal_check_start:83: comm kworker/u8:0: Detected aborted journal
[  217.348056] EXT4-fs (mmcblk0p2): Remounting filesystem read-only
[  217.348076] EXT4-fs error (device mmcblk0p2) in ext4_writepages:2856: IO failure
[  217.348079] EXT4-fs (mmcblk0p2): failed to convert unwritten extents to written extents -- potential data loss!  (inode 108110, error -30)
[  217.348634] EXT4-fs (mmcblk0p2): failed to convert unwritten extents to written extents -- potential data loss!  (inode 108110, error -30)
[  217.348963] EXT4-fs (mmcblk0p2): failed to convert unwritten extents to written extents -- potential data loss!  (inode 108114, error -30)
[  217.349014] EXT4-fs (mmcblk0p2): failed to convert unwritten extents to written extents -- potential data loss!  (inode 108116, error -30)
[  217.349153] EXT4-fs (mmcblk0p2): failed to convert unwritten extents to written extents -- potential data loss!  (inode 108117, error -30)
[  217.349325] EXT4-fs (mmcblk0p2): failed to convert unwritten extents to written extents -- potential data loss!  (inode 108111, error -30)
[  217.349366] EXT4-fs (mmcblk0p2): failed to convert unwritten extents to written extents -- potential data loss!  (inode 108113, error -30)
[  217.349455] EXT4-fs (mmcblk0p2): failed to convert unwritten extents to written extents -- potential data loss!  (inode 108115, error -30)
[  217.349507] EXT4-fs (mmcblk0p2): failed to convert unwritten extents to written extents -- potential data loss!  (inode 108112, error -30)
[ 1171.143967] EXT4-fs error (device mmcblk0p2): __ext4_remount:6425: comm mount: Abort forced by user

Thank you for your help!

Got it via balenaEtcher!
Thanks guys!

I still to customize it's vnc-server as I use headless CNC and install LinuxCNC itself. I didn't find it in the installed programs...
Will dig your framework deeper how to customize adding of the additional sources and gpg keys (to have linuxcnc, vscode, and sublime on the board).

Again - great work - The building process took about 30 minutes on 16 cores!

Decided to add some probably useful details :

1. After preparing the userdata.txt file I called "make menu" and went through all the UI (for bcm2711 arm64) till the end.

2. I used branch linuxcnc-2.9.2 of rpi-img-builder-lcnc according to Rod's suggestion.

3. I used default image size IMGSIZE="122880MB"

rodw wrote:

Yes, I used 20 cores....
You need to read and understand userdata.txt.
There are basically 3 steps.
1. Get the Pi kernel source and build the lernel
2. Build the root file system
3. Build the image.

The relevant preempt_rt patch 6.1.69-rt21 from kernel.org  is in userpatches
The commit is from the Raspberry 6.1.y kernel source github.com/raspberrypi/linux
This is the very next commit after the 6.1.69 kernel was merged into the raspberry kernel repo
This is important because without locking in the commit to get, the kernel can diverge a lot and it will become unstable with that patch
You could look for later  RT patches and find a later kernel release that matches it.
After the Pi5 was released it took a long time before such a merge happened or the happened out of step. The current version  is common for both the Pi5 and Pi4

Also from userdata.txt
### CUSTOM KERNEL - Comment out the one not required
CUSTOM_DEFCONFIG="0"
#MYCONFIG="linuxcnc-pi4_defconfig"
#MYCONFIG="linuxcnc-pi5_defconfig"
Once you configure the kernel with menuconfig, you can save the generated defconfig and tell it to use that. This means that on future builds, it skips menuconfig.

Also in custom.txt, try changing the image size to 12288MB. (12gb) This is how much memory is used when building the image. This might let you use the pi imager to burn the image. I found some bugs in their IMG shrink routine so made it big. I can't remember if the upstream changes have been merged in to fix this.

I installed network manager but Andy observed latency got worse so I took it out. You could add it to USER_PKGS 
github.com/rodw-au/rpi-img-builder-lcnc/...ata.txt#L24C1-L24C11

I deliberately kept the image as standard as possible to stay as close to what the x86 installer offers
 

Hello, today I have a pleasure to test your build system. First of all - it is really great work, thanks again!
I started with the default settings (mostly) and successfully built the image, but I cannot write it to the SD Card as RPI Imager says something like "Input file is not a valid image file. File size 3,795,000,000 is not aligned by 512 bytes" (it isn't the exact error message, my translation from my localized version, not sure how to change UI language there). RPI Imager v.1.8.5 (latest available).
Very probably something wrong with my settings or steps.

Configuration changes:
custom.txt:
HOSTNAME="pi-cnc"

userdata.txt
NAME="Andrey"
USERNAME="ago"
PASSWORD="*"
VERBOSE="1"
COMPRESS_IMG="1"
ENABLE_COMMIT="1"
COMMIT="342c7ee49e862edc30c893f141f55b9211b7a43b"
KBUSER="ago"
KBHOST="pc-cnc"

After preparing these files manually and ensuring that the board.txt file created 


I also received file .cache/git_fast.linux-rpi-6.1.y
GIT_FAST="true"
GIT_COMMIT="afd5f659b0453e4c710ce5cf74c577563ff16239"

Output files:
rpi-4-debian-bookworm-6.1.77-rt21-arm64-ext4-2024-02-25-2312.img.xz
rpi-4-debian-bookworm-6.1.77-rt21-arm64-ext4-2024-02-25-2312.img.xz.sha256
output/bcm2711/linux-headers-bcm2711-rpi-4_6.1.77-rt21-1_arm64.deb
output/bcm2711/linux-image-bcm2711-rpi-4_6.1.77-rt21-1_arm64.deb
output/logs (attached)

I will be very pleased if you can suggest something to move on.
Thank you!

 

Bugger hey, but like I said the value isn't a "memory" value but a disk image value.

Once I get this effing diabetes under control I'll pop down in the garage and start doing some real world testing of Linuxcnc on the Raspberry Pi image and the image built via the image maker....and see if the gvfs modules and network manager are an issue, from previous experience I don't see it being such an issue to make it unusable with mesa hardware, maybe direct gpio with a base & servo thread maybe a different kettle of fish . Wont be on the mill as I don't want to delve into the control box, but on the Frankenstein Myford ML7/Super 7. Reminds me I'll have to jerry rig something up for the spindle encoder.

cornholio wrote:

What changes were they ?
Even from the beginning that number referred to file size for the that the partitions and file systems .
 

In their changed scripts they attempted to do some maths to work out the size to use and they got it way wrong.  And of course i was the crash dummy that found the bug which was painful for a few days... But they fixed it.

What changes were they ?
Even from the beginning that number referred to file size for the that the partitions and file systems .

cornholio wrote:

Small correction it’s not the amount of memory used to build the image it’s the size of the file on disk used to create the boot & root partitions and file systems in, later on during the process these are mounted, as you would a physical disk partition, as well as some of the “virtual” file systems, and qemu “boots” and your have your virtual arm64 machine, and this is the environment that everything is installed for the final file system.
Actually after the image has been finalised you can start a qemu session with it and make any fine adjustments and these will be in the image after you exit the qemu session. I haven’t attempted a full GUI session but a text mode session is fine. Of course you need to setup and mount the image and add the virtual file systems before hand, but if you look through the code you’ll see how this is done.
Basically the same as when you create a virtual machine with say for example VirtualBox. You’re asked how big you want your disk to be. Then a file is created (can be a fixed size or dynamically allocated) and when you boot partitions and file systems are created in the file.

I suspect you missed the pain caused by buggy changes made by upstream that broke my build....

Small correction it’s not the amount of memory used to build the image it’s the size of the file on disk used to create the boot & root partitions and file systems in, later on during the process these are mounted, as you would a physical disk partition, as well as some of the “virtual” file systems, and qemu “boots” and your have your virtual arm64 machine, and this is the environment that everything is installed for the final file system.
Actually after the image has been finalised you can start a qemu session with it and make any fine adjustments and these will be in the image after you exit the qemu session. I haven’t attempted a full GUI session but a text mode session is fine. Of course you need to setup and mount the image and add the virtual file systems before hand, but if you look through the code you’ll see how this is done.
Basically the same as when you create a virtual machine with say for example VirtualBox. You’re asked how big you want your disk to be. Then a file is created (can be a fixed size or dynamically allocated) and when you boot partitions and file systems are created in the file.

Yes, I used 20 cores....
You need to read and understand userdata.txt.
There are basically 3 steps.
1. Get the Pi kernel source and build the lernel
2. Build the root file system
3. Build the image.

The relevant preempt_rt patch 6.1.69-rt21 from kernel.org  is in userpatches
The commit is from the Raspberry 6.1.y kernel source github.com/raspberrypi/linux
This is the very next commit after the 6.1.69 kernel was merged into the raspberry kernel repo
This is important because without locking in the commit to get, the kernel can diverge a lot and it will become unstable with that patch
You could look for later  RT patches and find a later kernel release that matches it.
After the Pi5 was released it took a long time before such a merge happened or the happened out of step. The current version  is common for both the Pi5 and Pi4

Also from userdata.txt
### CUSTOM KERNEL - Comment out the one not required
CUSTOM_DEFCONFIG="0"
#MYCONFIG="linuxcnc-pi4_defconfig"
#MYCONFIG="linuxcnc-pi5_defconfig"
Once you configure the kernel with menuconfig, you can save the generated defconfig and tell it to use that. This means that on future builds, it skips menuconfig.

Also in custom.txt, try changing the image size to 12288MB. (12gb) This is how much memory is used when building the image. This might let you use the pi imager to burn the image. I found some bugs in their IMG shrink routine so made it big. I can't remember if the upstream changes have been merged in to fix this.

I installed network manager but Andy observed latency got worse so I took it out. You could add it to USER_PKGS 
github.com/rodw-au/rpi-img-builder-lcnc/...ata.txt#L24C1-L24C11

I deliberately kept the image as standard as possible to stay as close to what the x86 installer offers




 

1 it’s the host and user name for the final image.
2 the commit is from the RPi kernel source
3 the script applies the patch

Rods script creates a purely Debian based image, completely different to the Official Raspberry Pi image.
The config.txt file is in a different location, some of the RPi utilities aren’t there. There’s no GUI network manager, rod claims this adds latency, but when I produced images with it included no one complained about any latency issues, apart from one user comparing their image that isolated 2 cores and the one I provided having no cores isolated. The gvfs modules I also included, again no complaints about latency issues.
My thought on the issue, the official RPi image is a double edged sword, everything is there to get up and going, but lacks some of the things included in the official Raspberry Pi Foundation images, as well as the config.txt and boot.txt being in different locations. So on one hand being an easy way to get up and going but a little confusing if the docs aren’t read.
To get an understanding of how the build scripts work you need to read through the sources, it’s not all that complicated and it’s quite modular. Getting the locales to work was a bit hit and miss to begin with.
Rod has put some really hard work into the image builder, during the initial stages we were bouncing ideas off each other, I had a few different ideas of the build process and what should be included and what not, but it was his baby from the beginning I really didn’t push the point.
It’s good and works.

Hello! I've started playing around with point 2 from your reply - it really faster to build a kernel on 16 adult cores instead 4 children - thanks a lot, great job!
Can I ask you the questions about some parameters?

1. What are these two?
### WHOAMI AND HOST
KBUSER="linuxcnc"
KBHOST="raspberrypi"
2. Commit - it is from linuxcnc repo, right?
COMMIT="342c7ee49e862edc30c893f141f55b9211b7a43b
3. rt-patch is automatically taken fresh or it is assumed that I had to update it manually?

Thnks again!

sudo apt install notification-daemon still produces the same error message after installation.

Is any configuration of the notification-daemon needed or should a installation be enough?

What I see is the linuxcnc startup logo and then the same error message is received. Same as before.