Phil McKerracher wrote:
>> I'm a little skeptical about this...  the "dd" is known to blow away the
>> formatting and partitioning of your disk...
> 
> What I found was that DD appeared to complete, but with the symptoms I
> described before - the 4801 would boot but not all the way. When I tried
> formatting the second partition afterwards using fdisk in Ubuntu though,
> it wouldn't let me - it complained of multiple errors in the partitioning,
> four "phantom" partititions that it wouldn't let me delete, clusters with
> negative offsets etc. I couldn't find any way using Ubuntu to clear these
> errors (which I believe were caused by physdiskwrite).
> 
> After completely reformatting the CF in Windows (and testing that I didn't
> have a faulty card) I then re-ran DD and then fdisk in Ubuntu. This time I
> could create and format the second partition OK, and it all ran on the
> 4801 at last.
> 
> This is all repeatable, by the way - I went around the loop a couple of
> times because I didn't believe it myself.

I appreciate that you say this is what's happening, but dd does a block 
by block copy from the image file to the physical hard drive, including 
the partition table.  Please type paste the EXACT command you are using 
with dd and we'll be able to more easily diagnose how this is not working.

> I never did get physdiskwrite to work properly in Vista, even after
> disabling UAC, setting win2k compatibility mode, running as administrator,
> using the -u option etc. It sometimes produced a card that appeared to
> have the right files on it, but never a card that would actually boot all
> the way in the 4801. And it always gives a "write error" message.

I can't even begin to guess why Vista won't work.  If someone could 
research this on the m0n0wall mailing list, it may help some other 
people in the future.

> I'm guessing it's impossible to completely generate the CF card in Vista
> because there's no way to format the second partition in Linux (83)
> format, and without it there's no way to get to the command prompt on the
> 4801 to do it there.

You're not intended to create a Linux partition in Windows...  please 
read below and in the documentation.

>> Sounds like you need to mount your ASTURW filesystem, and then generated
>> your kd...
>>
>> Running "genunion" from the CLI should do this.
> 
> I ran genunion and rebooted and it appeared to complete successfully.
> Editing the main configuration using the web interface (and saving the
> changes, obviously!) also appeared to work, but the changes were gone when
> I rebooted. So either genunion didn't actually work, or the web interface
> is changing the wrong file and it's being overwritten somehow, or there's
> a problem with permissions. I haven't had a chance yet to investigate
> further.
> 
> Does anyone have suggestions for diagnosing the problem?

Yes.  Please read the documentation completely on the Astlinux page, 
specifically this page:

http://www.astlinux.org/node/36

Start at #3, then read and execute the remaining steps.  If you do steps 
  1,2,3 and 5 without 4 you can't expect things to work!

Darrick

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