initramfs+modules: robust copy aliasing, curated stage1 + PHYs, firmware policy via firmware.conf, runtime readiness, build ID; docs sync

Summary of changes (with references):\n\nModules + PHY coverage\n- Curated and normalized stage1 list in [config.modules.conf](config/modules.conf:1):\n  - Boot-critical storage, core virtio, common NICs (Intel/Realtek/Broadcom), overlay/fuse, USB HCD/HID.\n  - Added PHY drivers required by NIC MACs:\n    * realtek (for r8169, etc.)\n    * broadcom families: broadcom, bcm7xxx, bcm87xx, bcm_phy_lib, bcm_phy_ptp\n- Robust underscore↔hyphen aliasing during copy so e.g. xhci_pci → xhci-pci.ko, hid_generic → hid-generic.ko:\n  - [bash.initramfs_copy_resolved_modules()](scripts/lib/initramfs.sh:990)\n\nFirmware policy and coverage\n- Firmware selection now authoritative via [config/firmware.conf](config/firmware.conf:1); ignore modules.conf firmware hints:\n  - [bash.initramfs_setup_modules()](scripts/lib/initramfs.sh:229)\n  - Count from firmware.conf for reporting; remove stale required-firmware.list.\n- Expanded NIC firmware set (bnx2, bnx2x, tigon, intel, realtek, rtl_nic, qlogic, e100) in [config.firmware.conf](config/firmware.conf:1).\n- Installer enforces firmware.conf source-of-truth in [bash.alpine_install_firmware()](scripts/lib/alpine.sh:392).\n\nEarly input & build freshness\n- Write a runtime build stamp to /etc/zero-os-build-id for embedded initramfs verification:\n  - [bash.initramfs_finalize_customization()](scripts/lib/initramfs.sh:568)\n- Minor init refinements in [config.init](config/init:1) (ensures /home, consistent depmod path).\n\nRebuild helper improvements\n- [scripts/rebuild-after-zinit.sh](scripts/rebuild-after-zinit.sh:1):\n  - Added --verify-only; container-aware execution; selective marker clears only.\n  - Prints stage status before/after; avoids --rebuild-from; resolves full kernel version for diagnostics.\n\nRemote flist readiness + zinit\n- Init scripts now probe BASE_URL readiness and accept FLISTS_BASE_URL/FLIST_BASE_URL; firmware target is /lib/firmware:\n  - [sh.firmware.sh](config/zinit/init/firmware.sh:1)\n  - [sh.modules.sh](config/zinit/init/modules.sh:1)\n\nContainer, docs, and utilities\n- Stream container build logs by calling runtime build directly in [bash.docker_build_container()](scripts/lib/docker.sh:56).\n- Docs updated to reflect firmware policy, runtime readiness, rebuild helper, early input, and GRUB USB:\n  - [docs.NOTES.md](docs/NOTES.md)\n  - [docs.PROMPT.md](docs/PROMPT.md)\n  - [docs.review-rfs-integration.md](docs/review-rfs-integration.md)\n- Added GRUB USB creator (referenced in docs): [scripts/make-grub-usb.sh](scripts/make-grub-usb.sh)\n\nCleanup\n- Removed legacy/duplicated config trees under configs/ and config/zinit.old/.\n- Minor newline and ignore fixes: [.gitignore](.gitignore:1)\n\nNet effect\n- Runtime now has correct USB HCDs/HID-generic and NIC+PHY coverage (Realtek/Broadcom), with matching firmware installed in initramfs.\n- Rebuild workflow is minimal and host/container-aware; docs are aligned with implemented behavior.\n

AGENTS.md

@@ -0,0 +1,33 @@
+# AGENTS.md
+
+This file provides guidance to agents when working with code in this repository.
+
+Non-obvious build/run facts (read from scripts):
+- Always build inside the containerized toolchain; ./scripts/build.sh will spawn a transient container, or use the persistent dev container via ./scripts/dev-container.sh start then ./scripts/dev-container.sh build.
+- The incremental pipeline is stage-driven with .build-stages markers; list status via ./scripts/build.sh --show-stages and force a subset with --rebuild-from=<stage>.
+- Outputs are anchored to PROJECT_ROOT (normalized in [bash.common.sh](scripts/lib/common.sh:236)):
+  - Kernel: dist/vmlinuz.efi (created by [bash.kernel_build_with_initramfs()](scripts/lib/kernel.sh:174))
+  - Initramfs archive: dist/initramfs.cpio.xz (created by [bash.initramfs_create_cpio()](scripts/lib/initramfs.sh:688))
+- Kernel embeds the initramfs (CONFIG_INITRAMFS_SOURCE set by [bash.kernel_modify_config_for_initramfs()](scripts/lib/kernel.sh:130)); no separate initrd is required in normal flow.
+
+Fast iteration helpers (init/zinit/modules.conf):
+- Use ./scripts/rebuild-after-zinit.sh to re-copy /init, re-apply zinit, re-resolve/copy modules, and recreate the cpio (initramfs-only by default).
+  - Flags: --with-kernel (also re-embed kernel; forces --rebuild-from=initramfs_create), --refresh-container-mods (rebuild container /lib/modules if missing), --verify-only (report changes since last cpio).
+- DEBUG=1 shows full safe_execute logs and stage timings.
+
+Critical conventions (avoid breakage):
+- Use logging/safety helpers from [bash.common.sh](scripts/lib/common.sh:1): log_info/warn/error/debug, safe_execute, section_header.
+- Paths must be anchored to PROJECT_ROOT (already normalized after sourcing config) to avoid CWD drift (kernel builds cd into kernel/current).
+- Do not edit /etc/shadow directly; passwordless root is applied by chroot ${initramfs_dir} passwd -d root in [bash.initramfs_finalize_customization()](scripts/lib/initramfs.sh:575).
+- initdebug=true on kernel cmdline opens an early shell from [config/init](config/init) even without /init-debug.
+
+Modules and firmware (non-obvious flow):
+- Container /lib/modules/<FULL_VERSION> is the authoritative source for dependency resolution and copying into initramfs (ensure kernel_modules stage ran at least once).
+- RFS firmware pack now installs all linux-firmware* into container and packs from /lib/firmware; runtime overmount targets /lib/firmware (not /usr/lib/firmware).
+
+Troubleshooting gotchas:
+- If “Initramfs directory not found: initramfs” or kernel output in wrong place, path anchoring patches exist in [bash.initramfs_create_cpio()](scripts/lib/initramfs.sh:688), [bash.initramfs_validate()](scripts/lib/initramfs.sh:799), and [bash.kernel_build_with_initramfs()](scripts/lib/kernel.sh:174); ensure DEBUG logs show “... anchored to PROJECT_ROOT”.
+- On host, the rebuild helper delegates to ./scripts/dev-container.sh so you don’t need to manually start the container.
+
+Utilities:
+- Create BIOS+UEFI USB with embedded-initramfs kernel: sudo ./scripts/make-grub-usb.sh /dev/sdX --kparams "console=ttyS0 initdebug=true" (use --with-initrd only if you want a separate initrd on ESP).

config/firmware.conf

@@ -2,12 +2,15 @@
 # Alpine Linux provides separate firmware packages for hardware support
 # Format: FIRMWARE_PACKAGE:DESCRIPTION
 
-# Essential network firmware packages
+# Essential network firmware packages (wired NICs matching stage1 drivers)
-linux-firmware-bnx2:Broadcom NetXtreme firmware
+linux-firmware-bnx2:Broadcom NetXtreme (bnx2) firmware
+linux-firmware-bnx2x:Broadcom NetXtreme II (bnx2x) firmware
+linux-firmware-tigon:Broadcom tg3 (Tigon) firmware
 linux-firmware-e100:Intel PRO/100 firmware
-linux-firmware-intel:Intel network and WiFi firmware (includes e1000e, igb, ixgbe, i40e, ice)
+linux-firmware-intel:Intel NIC firmware (covers e1000e, igb, ixgbe, i40e, ice)
-linux-firmware-realtek:Realtek network firmware (r8169, etc.)
+linux-firmware-rtl_nic:Realtek NIC firmware (r8169, etc.)
-linux-firmware-qlogic:QLogic network firmware
+linux-firmware-realtek:Realtek NIC firmware (meta)
+linux-firmware-qlogic:QLogic NIC firmware
 
 # Storage firmware (if needed)
 # linux-firmware-marvell:Marvell storage/network firmware (not available in Alpine 3.22)

config/init

@@ -1,4 +1,4 @@
-#!/bin/sh -x
+#!/bin/sh
 # Alpine-based Zero-OS Init Script
 # Maintains identical flow to original busybox version
 
@@ -24,11 +24,8 @@ mount -t devtmpfs devtmpfs /dev
 mkdir -p /dev/pts
 mount -t devpts devpts /dev/pts
 
-# Early debug shell if kernel parameter initdebug=true is present
+# Re-initialize modules dependencies for basic init
-if grep -qw "initdebug=true" /proc/cmdline; then
+depmod -a
-    echo "[+] initdebug=true detected; starting emergency shell. Type 'exit' to continue boot."
-    /bin/sh -l
-fi
 
 echo "[+] building ram filesystem"
 
@@ -52,6 +49,8 @@ echo "  copying /var..."
 cp -ar /var $target
 echo "  copying /run..."
 cp -ar /run $target
+echo "  creating /home"
+mkdir $target/home
 
 # Create essential directories
 mkdir -p $target/dev
@@ -77,45 +76,41 @@ if [ -x /sbin/udevd ]; then
     echo "  starting udevd..."
     udevd --daemon
     
+    # Preload keyboard input modules early so console works before zinit and rfs mounts
+    echo "[+] preloading keyboard input modules"
+    for m in i8042 atkbd usbhid hid hid_generic evdev xhci_pci xhci_hcd ehci_pci ehci_hcd ohci_pci ohci_hcd uhci_hcd; do
+        modprobe "$m" 
+    done
+    echo "[+] loading essential drivers"
+    # Load core drivers for storage and network
+    /bin/busybox sh -l
+    modprobe btrfs 2>/dev/null || true
+    modprobe fuse 2>/dev/null || true
+    modprobe overlay 2>/dev/null || true
+
+    # Load storage drivers
+    modprobe ahci 2>/dev/null || true
+    modprobe nvme 2>/dev/null || true
+    modprobe virtio_blk 2>/dev/null || true
+    modprobe virtio_scsi 2>/dev/null || true
+    modprobe virtio_pci 2>/dev/null || true
+
+    # Load network drivers  
+    modprobe virtio_net 2>/dev/null || true
+        
     echo "  triggering device discovery..."
     udevadm trigger --action=add --type=subsystems
     udevadm trigger --action=add --type=devices
+    udevadm trigger --action=add
     udevadm settle
     
     echo "  stopping udevd..."
+    
     kill $(pidof udevd) || true
 else
     echo "  warning: udevd not found, skipping hardware detection"
 fi
 
-echo "[+] loading essential drivers"
-# Load core drivers for storage and network
-modprobe btrfs 2>/dev/null || true
-modprobe fuse 2>/dev/null || true
-modprobe overlay 2>/dev/null || true
-
-# Load storage drivers
-modprobe ahci 2>/dev/null || true
-modprobe nvme 2>/dev/null || true
-modprobe virtio_blk 2>/dev/null || true
-modprobe virtio_scsi 2>/dev/null || true
-modprobe virtio_pci 2>/dev/null || true
-
-# Load network drivers  
-modprobe virtio_net 2>/dev/null || true
-modprobe e1000 2>/dev/null || true
-modprobe e1000e 2>/dev/null || true
-
-echo "[+] loading USB keyboard support"
-modprobe usbcore
-modprobe ehci-hcd
-modprobe xhci-hcd
-modprobe usbhid
-modprobe evdev
-
-# Unmount init filesystems
-umount /proc 2>/dev/null || true
-umount /sys 2>/dev/null || true
 
 echo "[+] debug hook: initdebug=true or /init-debug"
 if grep -qw "initdebug=true" /proc/cmdline; then
@@ -124,16 +119,23 @@ if grep -qw "initdebug=true" /proc/cmdline; then
         sh /init-debug
     else
         echo "  initdebug=true: starting interactive shell (no /init-debug). Type 'exit' to continue."
-        /bin/sh -l
+        debug="-d"
+        /bin/busybox sh
     fi
 elif [ -x /init-debug ]; then
     echo "  executing /init-debug ..."
     sh /init-debug
 fi
 
-echo "[+] switching root"
+# Unmount init filesystems
-mkdir /root/home
+umount /proc 2>/dev/null || true
-echo "  exec switch_root /mnt/root /sbin/zinit init"
+umount /sys 2>/dev/null || true
-exec switch_root /mnt/root /sbin/zinit -d init
 
+
+echo "[+] switching root"
+echo "  exec switch_root /mnt/root /sbin/zinit init"
+exec switch_root /mnt/root /sbin/zinit ${debug} init
+
+# switch_root failed, drop into shell
+/bin/busybox sh
 ##

config/kernel.config

@@ -1,6 +1,6 @@
 #
 # Automatically generated file; DO NOT EDIT.
-# Linux/x86 6.12.42 Kernel Configuration
+# Linux/x86 6.12.44 Kernel Configuration
 #
 CONFIG_CC_VERSION_TEXT="gcc (Alpine 14.2.0) 14.2.0"
 CONFIG_CC_IS_GCC=y
@@ -11,8 +11,8 @@ CONFIG_AS_VERSION=24400
 CONFIG_LD_IS_BFD=y
 CONFIG_LD_VERSION=24400
 CONFIG_LLD_VERSION=0
-CONFIG_RUSTC_VERSION=108900
+CONFIG_RUSTC_VERSION=109000
-CONFIG_RUSTC_LLVM_VERSION=200107
+CONFIG_RUSTC_LLVM_VERSION=200108
 CONFIG_CC_CAN_LINK=y
 CONFIG_CC_CAN_LINK_STATIC=y
 CONFIG_CC_HAS_ASM_GOTO_OUTPUT=y
@@ -22,7 +22,7 @@ CONFIG_CC_HAS_ASM_INLINE=y
 CONFIG_CC_HAS_NO_PROFILE_FN_ATTR=y
 CONFIG_LD_CAN_USE_KEEP_IN_OVERLAY=y
 CONFIG_RUSTC_HAS_UNNECESSARY_TRANSMUTES=y
-CONFIG_PAHOLE_VERSION=0
+CONFIG_PAHOLE_VERSION=130
 CONFIG_IRQ_WORK=y
 CONFIG_BUILDTIME_TABLE_SORT=y
 CONFIG_THREAD_INFO_IN_TASK=y
@@ -235,7 +235,7 @@ CONFIG_CHECKPOINT_RESTORE=y
 CONFIG_SCHED_AUTOGROUP=y
 CONFIG_RELAY=y
 CONFIG_BLK_DEV_INITRD=y
-CONFIG_INITRAMFS_SOURCE="../../root"
+CONFIG_INITRAMFS_SOURCE="/workspace/dist/initramfs.cpio.xz"
 CONFIG_INITRAMFS_ROOT_UID=0
 CONFIG_INITRAMFS_ROOT_GID=0
 # CONFIG_RD_GZIP is not set
@@ -2142,7 +2142,9 @@ CONFIG_FW_LOADER_SYSFS=y
 CONFIG_EXTRA_FIRMWARE=""
 CONFIG_FW_LOADER_USER_HELPER=y
 # CONFIG_FW_LOADER_USER_HELPER_FALLBACK is not set
-# CONFIG_FW_LOADER_COMPRESS is not set
+CONFIG_FW_LOADER_COMPRESS=y
+CONFIG_FW_LOADER_COMPRESS_XZ=y
+CONFIG_FW_LOADER_COMPRESS_ZSTD=y
 CONFIG_FW_CACHE=y
 # CONFIG_FW_UPLOAD is not set
 # end of Firmware loader

config/modules.conf

@@ -1,57 +1,74 @@
 # Module loading specification for Zero-OS Alpine initramfs
-# Format: STAGE:MODULE_NAME:FIRMWARE_PACKAGE (optional)
+# Format: STAGE:MODULE
-# Focus on most common NIC modules to ensure networking works on most hardware
+# Firmware selection is authoritative in config/firmware.conf; do not add firmware hints here.
 
-# Stage 1: Core subsystems + networking and essential boot modules
+# Stage 1: boot-critical storage, core virtio, networking, overlay, and input (USB/HID/keyboard)
-# All core subsystems and NICs must be loaded BEFORE network can come up
-stage1:virtio:none                      # Core virtio subsystem (REQUIRED)
-stage1:virtio_ring:none                 # Virtio ring buffer (REQUIRED)
-stage1:virtio_pci:none                  # Virtio PCI bus
-stage1:virtio_net:none                  # Virtio network (VMs, cloud)
-stage1:virtio_scsi:none                 # Virtio SCSI (VMs, cloud)
-stage1:virtio_blk:none                  # Virtio block (VMs, cloud)
-stage1:e1000:linux-firmware-intel       # Intel E1000 (very common)
-stage1:e1000e:linux-firmware-intel      # Intel E1000E (very common)
-stage1:r8169:linux-firmware-realtek     # Realtek (most common desktop/server)
-stage1:realtek:linux-firmware-realtek     # Realtek (most common desktop/server)
-stage1:igb:linux-firmware-intel         # Intel Gigabit (servers)
-stage1:ixgbe:linux-firmware-intel       # Intel 10GbE (servers)
-stage1:i40e:linux-firmware-intel        # Intel 40GbE (modern servers)
-stage1:ice:linux-firmware-intel         # Intel E800 series (latest)
-stage1:8139too:none                     # Realtek 8139 (legacy)
-stage1:8139cp:none                      # Realtek 8139C+ (legacy)
-stage1:bnx2:linux-firmware-bnx2         # Broadcom NetXtreme
-stage1:bnx2x:linux-firmware-bnx2        # Broadcom NetXtreme II
-stage1:tg3:none                         # Broadcom Tigon3
-stage1:b44:none                         # Broadcom 44xx
-stage1:atl1:none                        # Atheros L1
-stage1:atl1e:none                       # Atheros L1E
-stage1:atl1c:none                       # Atheros L1C
-stage1:alx:none                         # Atheros Alx
-stage1:libata:none                      # Core ATA subsystem (REQUIRED)
-stage1:scsi_mod:none                    # SCSI subsystem
-stage1:sd_mod:none                      # SCSI disk support
-stage1:ahci:none                        # SATA AHCI
-stage1:nvme_core:none                   # Core NVMe subsystem (REQUIRED)
-stage1:nvme:none                        # NVMe storage
-stage1:tun:none                         # TUN/TAP for networking
-stage1:overlay:none                     # OverlayFS for containers
-stage1:fuse:none                        # OverlayFS for containers
 
-# Stage 1: USB keyboard support (host controllers + HID)
+# Storage
-stage1:xhci_pci:none
+stage1:libata
-stage1:xhci_hcd:none
+stage1:libahci
-stage1:ehci_pci:none
+stage1:ahci
-stage1:ehci_hcd:none
+stage1:scsi_mod
-stage1:ohci_pci:none
+stage1:sd_mod
-stage1:ohci_hcd:none
+stage1:nvme_core
-stage1:uhci_hcd:none
+stage1:nvme
-stage1:usbhid:none
+stage1:virtio_blk
-stage1:hid_generic:none
+stage1:virtio_scsi
-stage1:hid:none
-stage1:atkbd:none
-stage1:libps2:none
-stage1:i2c_smbus:none
-stage1:serio:none
-stage1:i8042i:none
 
+# Core virtio
+stage1:virtio
+stage1:virtio_ring
+stage1:virtio_pci
+stage1:virtio_pci_legacy_dev
+stage1:virtio_pci_modern_dev
+
+# Networking (common NICs)
+stage1:virtio_net
+stage1:e1000
+stage1:e1000e
+stage1:igb
+stage1:ixgbe
+stage1:igc
+stage1:i40e
+stage1:ice
+stage1:r8169
+stage1:8139too
+stage1:8139cp
+stage1:bnx2
+stage1:bnx2x
+stage1:tg3
+stage1:tun
+
+# PHY drivers
+stage1:realtek
+# Broadcom PHY families (required for many Broadcom NICs)
+stage1:broadcom
+stage1:bcm7xxx
+stage1:bcm87xx
+stage1:bcm_phy_lib
+stage1:bcm_phy_ptp
+
+# Filesystems / overlay
+stage1:overlay
+stage1:fuse
+
+# USB host controllers and HID/keyboard input
+stage1:xhci_pci
+stage1:xhci_hcd
+stage1:ehci_pci
+stage1:ehci_hcd
+stage1:ohci_pci
+stage1:ohci_hcd
+stage1:uhci_hcd
+stage1:usbhid
+stage1:hid_generic
+stage1:hid
+stage1:atkbd
+stage1:libps2
+stage1:i8042
+stage1:evdev
+stage1:serio_raw
+stage1:serio
+
+# Keep stage2 empty; we only use stage1 in this build
+# stage2: (intentionally unused)

config/zinit.old/cgroup.yaml

@@ -1,2 +0,0 @@
-exec: sh /etc/zinit/init/cgroup.sh
-oneshot: true

config/zinit.old/depmod.yaml

@@ -1 +0,0 @@
-exec: depmod -a

config/zinit.old/getty.yaml

@@ -1,2 +0,0 @@
-exec: /sbin/getty -L 115200 ttyS0 vt100
-restart: always

config/zinit.old/gettyconsole.yaml

@@ -1,2 +0,0 @@
-exec: /sbin/getty console linux
-restart: always

config/zinit.old/haveged.yaml

@@ -1,2 +0,0 @@
-exec: haveged -w 1024 -d 32 -i 32 -v 1
-oneshot: true

config/zinit.old/init/ashloging.sh

@@ -1,6 +0,0 @@
-#!/bin/bash
-
-echo "start ash terminal"
-while true; do
-    getty -l /bin/ash -n 19200 tty2
-done

config/zinit.old/init/cgroup.sh

@@ -1,10 +0,0 @@
-set -x
-
-mount -t tmpfs cgroup_root /sys/fs/cgroup
-
-subsys="pids cpuset cpu cpuacct blkio memory devices freezer net_cls perf_event net_prio hugetlb"
-
-for sys in $subsys; do
-    mkdir -p /sys/fs/cgroup/$sys
-    mount -t cgroup $sys -o $sys /sys/fs/cgroup/$sys/
-done

config/zinit.old/init/modprobe.sh

@@ -1,10 +0,0 @@
-#!/bin/bash
-
-modprobe fuse
-modprobe btrfs
-modprobe tun
-modprobe br_netfilter
-
-echo never > /sys/kernel/mm/transparent_hugepage/enabled
-
-ulimit -n 524288

config/zinit.old/init/ntpd.sh

@@ -1,10 +0,0 @@
-#!/bin/sh
-
-ntp_flags=$(grep -o 'ntp=.*' /proc/cmdline | sed 's/^ntp=//')
-
-params=""
-if [ -n "$ntp_flags" ]; then
-  params=$(echo "-p $ntp_flags" | sed s/,/' -p '/g)
-fi
-
-exec ntpd -n $params

config/zinit.old/init/routing.sh

@@ -1,4 +0,0 @@
-#!/bin/bash
-
-echo "Enable ip forwarding"
-echo 1 > /proc/sys/net/ipv4/ip_forward

config/zinit.old/init/shm.sh

@@ -1,3 +0,0 @@
-#!/bin/sh
-mkdir /dev/shm
-mount -t tmpfs shm /dev/shm 

config/zinit.old/init/sshd-setup.sh

@@ -1,15 +0,0 @@
-#!/bin/ash
-if [ -f /etc/ssh/ssh_host_rsa_key ]; then
-    # ensure existing file permissions
-    chown root:root /etc/ssh/ssh_host_*
-    chmod 600 /etc/ssh/ssh_host_*
-    exit 0
-fi
-
-echo "Setting up sshd"
-mkdir -p /run/sshd
-
-ssh-keygen -f /etc/ssh/ssh_host_rsa_key -N '' -t rsa
-ssh-keygen -f /etc/ssh/ssh_host_dsa_key -N '' -t dsa
-ssh-keygen -f /etc/ssh/ssh_host_ecdsa_key -N '' -t ecdsa -b 521
-ssh-keygen -f /etc/ssh/ssh_host_ed25519_key -N '' -t ed25519

config/zinit.old/init/udev.sh

@@ -1,4 +0,0 @@
-#!/bin/sh
-
-udevadm trigger --action=add
-udevadm settle

config/zinit.old/lo.yaml

@@ -1,2 +0,0 @@
-exec: ip l set lo up
-oneshot: true

config/zinit.old/local-modprobe.yaml

@@ -1,2 +0,0 @@
-exec: sh /etc/zinit/init/modprobe.sh
-oneshot: true

config/zinit.old/mycelium.yaml

@@ -1,6 +0,0 @@
-exec: /usr/bin/mycelium --key-file /tmp/mycelium_priv_key.bin
-  --tun-name my0 --silent --peers tcp://188.40.132.242:9651 tcp://136.243.47.186:9651
-  tcp://185.69.166.7:9651 tcp://185.69.166.8:9651 tcp://65.21.231.58:9651 tcp://65.109.18.113:9651
-  tcp://209.159.146.190:9651 tcp://5.78.122.16:9651 tcp://5.223.43.251:9651 tcp://142.93.217.194:9651
-after:
-  - network

config/zinit.old/network.yaml

@@ -1,5 +0,0 @@
-exec: dhcpcd eth0
-after:
-  - depmod
-  - udevd
-  - udev-trigger

config/zinit.old/ntp.yaml

@@ -1,3 +0,0 @@
-exec: sh /etc/zinit/init/ntpd.sh
-after:
-  - network

config/zinit.old/routing.yaml

@@ -1,2 +0,0 @@
-exec: sh /etc/zinit/init/routing.sh
-oneshot: true

config/zinit.old/shm.yaml

@@ -1,2 +0,0 @@
-exec: /etc/zinit/init/shm.sh
-oneshot: true

config/zinit.old/sshd-setup.yaml

@@ -1,2 +0,0 @@
-exec: sh /etc/zinit/init/sshd-setup.sh
-oneshot: true

config/zinit.old/sshd.yaml

@@ -1,3 +0,0 @@
-exec: /usr/sbin/sshd -D -e
-after:
-    - sshd-setup

config/zinit.old/udev-trigger.yaml

@@ -1,6 +0,0 @@
-exec: sh /etc/zinit/init/udev.sh
-oneshot: true
-after:
-  - depmod
-  - udevmon
-  - udevd

config/zinit.old/udevd.yaml

@@ -1 +0,0 @@
-exec: udevd

config/zinit.old/udevmon.yaml

@@ -1 +0,0 @@
-exec: udevadm monitor

config/zinit.old/zinit.conf

@@ -1,33 +0,0 @@
-# Main zinit configuration for Zero OS Alpine
-# This replaces OpenRC completely
-
-# Logging configuration
-log_level: debug
-log_file: /var/log/zinit/zinit.log
-
-# Initialization phases
-init:
-  # Phase 1: Critical system setup
-  - stage1-modules
-  - udevd
-  - depmod
-  
-  # Phase 2: Extended hardware and networking
-  - stage2-modules
-  - network
-  - lo
-  
-  # Phase 3: System services
-  - routing
-  - ntp
-  - haveged
-  
-  # Phase 4: User services
-  - sshd-setup
-  - sshd
-  - getty
-  - console
-  - gettyconsole
-
-# Service dependencies and ordering managed by individual service files
-# All services are defined in the services/ subdirectory

config/zinit/console.yaml

@@ -1,2 +0,0 @@
-exec: /sbin/getty -L 9600 console
-restart: always

config/zinit/getty-console.yaml

@@ -1,2 +1,2 @@
-exec: /sbin/agetty --noclear -a root tty1  linux
+exec: /sbin/agetty --noclear -a root console  linux
 restart: always

config/zinit/getty-tty2.yaml

@@ -0,0 +1,2 @@
+exec: /sbin/agetty --noclear -a root tty2  vt100
+restart: always

config/zinit/haveged.yaml

@@ -1,2 +1,5 @@
 exec: haveged -w 1024 -d 32 -i 32 -v 1
 oneshot: true
+after: 
+  - shm
+  

config/zinit/init/firmware.sh

@@ -8,7 +8,38 @@ log() { echo "[rfs-firmware] $*"; }
 
 RFS_BIN="${RFS_BIN:-rfs}"
 TARGET="/lib/firmware"
-BASE_URL="${FLISTS_BASE_URL:-https://zos.grid.tf/store/flists}"
+
+# Accept both FLISTS_BASE_URL and FLIST_BASE_URL (alias); prefer FLISTS_BASE_URL
+if [ -n "${FLISTS_BASE_URL:-}" ]; then
+  BASE_URL="${FLISTS_BASE_URL}"
+elif [ -n "${FLIST_BASE_URL:-}" ]; then
+  BASE_URL="${FLIST_BASE_URL}"
+else
+  BASE_URL="https://zos.grid.tf/store/flists"
+fi
+
+# HTTP readiness helper: wait until BASE_URL responds to HTTP(S)
+wait_for_http() {
+  url="$1"
+  tries="${2:-60}"
+  delay="${3:-2}"
+  i=0
+  while [ "$i" -lt "$tries" ]; do
+    if command -v wget >/dev/null 2>&1; then
+      if wget -q --spider "$url"; then
+        return 0
+      fi
+    elif command -v busybox >/dev/null 2>&1; then
+      if busybox wget -q --spider "$url"; then
+        return 0
+      fi
+    fi
+    i=$((i+1))
+    log "waiting for $url (attempt $i/$tries)"
+    sleep "$delay"
+  done
+  return 1
+}
 
 # Allow override via env
 if [ -n "${FIRMWARE_FLIST:-}" ] && [ -f "${FIRMWARE_FLIST}" ]; then
@@ -29,11 +60,18 @@ else
 fi
 
 if [ -z "${FL:-}" ]; then
-  # Try remote fetch as a fallback
+  # Try remote fetch as a fallback (but first ensure BASE_URL is reachable)
   mkdir -p /etc/rfs
   FL="/etc/rfs/firmware-latest.fl"
-  URL="${BASE_URL}/firmware-latest.fl"
+  URL="${BASE_URL%/}/firmware-latest.fl"
-  log "firmware-latest.fl not found locally; fetching ${URL}"
+  log "firmware-latest.fl not found locally; will fetch ${URL}"
+
+  # Probe BASE_URL root so DNS/HTTP are ready before fetch
+  ROOT_URL="${BASE_URL%/}/"
+  if ! wait_for_http "$ROOT_URL" 60 2; then
+    log "BASE_URL not reachable yet: ${ROOT_URL}; continuing to attempt fetch anyway"
+  fi
+  log "fetching ${URL}"
 
   if command -v wget >/dev/null 2>&1; then
     wget -q -O "${FL}" "${URL}" || true

config/zinit/init/modprobe.sh

@@ -3,7 +3,17 @@
 modprobe fuse
 modprobe btrfs
 modprobe tun
-modprobe br_netfilter
+modprobe 
+
+modprobe usbhid
+modprobe hid_generic
+modprobe hid
+modprobe atkbd
+modprobe libps2
+modprobe i2c_smbus
+modprobe serio
+modprobe i8042i
+
 
 echo never > /sys/kernel/mm/transparent_hugepage/enabled
 

config/zinit/init/modules.sh

@@ -9,7 +9,37 @@ log() { echo "[rfs-modules] $*"; }
 RFS_BIN="${RFS_BIN:-rfs}"
 KVER="$(uname -r)"
 TARGET="/lib/modules/${KVER}"
-BASE_URL="${FLISTS_BASE_URL:-https://zos.grid.tf/store/flists}"
+# Accept both FLISTS_BASE_URL and FLIST_BASE_URL (alias); prefer FLISTS_BASE_URL
+if [ -n "${FLISTS_BASE_URL:-}" ]; then
+  BASE_URL="${FLISTS_BASE_URL}"
+elif [ -n "${FLIST_BASE_URL:-}" ]; then
+  BASE_URL="${FLIST_BASE_URL}"
+else
+  BASE_URL="https://zos.grid.tf/store/flists"
+fi
+
+# HTTP readiness helper: wait until BASE_URL responds to HTTP(S)
+wait_for_http() {
+  url="$1"
+  tries="${2:-60}"
+  delay="${3:-2}"
+  i=0
+  while [ "$i" -lt "$tries" ]; do
+    if command -v wget >/dev/null 2>&1; then
+      if wget -q --spider "$url"; then
+        return 0
+      fi
+    elif command -v busybox >/dev/null 2>&1; then
+      if busybox wget -q --spider "$url"; then
+        return 0
+      fi
+    fi
+    i=$((i+1))
+    log "waiting for $url (attempt $i/$tries)"
+    sleep "$delay"
+  done
+  return 1
+}
 
 # Allow override via env
 if [ -n "${MODULES_FLIST:-}" ] && [ -f "${MODULES_FLIST}" ]; then
@@ -33,8 +63,15 @@ if [ -z "${FL:-}" ]; then
   # Try remote fetch as a fallback (modules-<uname -r>-Zero-OS.fl)
   mkdir -p /etc/rfs
   FL="/etc/rfs/modules-${KVER}.fl"
-  URL="${BASE_URL}/modules-${KVER}-Zero-OS.fl"
+  URL="${BASE_URL%/}/modules-${KVER}-Zero-OS.fl"
-  log "modules-${KVER}.fl not found locally; fetching ${URL}"
+  log "modules-${KVER}.fl not found locally; will fetch ${URL}"
+
+  # Probe BASE_URL root so DNS/HTTP are ready before fetch
+  ROOT_URL="${BASE_URL%/}/"
+  if ! wait_for_http "$ROOT_URL" 60 2; then
+    log "BASE_URL not reachable yet: ${ROOT_URL}; continuing to attempt fetch anyway"
+  fi
+  log "fetching ${URL}"
 
   if command -v wget >/dev/null 2>&1; then
     wget -q -O "${FL}" "${URL}" || true

config/zinit/rfs-modules.yaml

@@ -1,4 +1,4 @@
 exec: sh /etc/zinit/init/modules.sh
 restart: always
 after:
-  - network
+  - rfs-modules

config/zinit/shm.yaml

@@ -1,5 +1,5 @@
 exec: /etc/zinit/init/shm.sh
 oneshot: true
 after:
-  - firmware
+  - rfs-modules
-  - modules
+  - rfs-firmware

config/zinit/sshd.yaml

@@ -1,3 +1,4 @@
 exec: /usr/sbin/sshd -D -e
 after:
     - sshd-setup
+    - shm

config/zinit/udev-rfs.yaml

@@ -1,5 +1,4 @@
-exec: /bin/sh -c "udevadm control --reload; udevadm trigger --action=add --type=subsystems; udevadm trigger --action=add --type=devices; udevadm settle"
+exec: sh -c "sleep 3 ; /etc/zinit/init/udev.sh"
 oneshot: true
 after:
   - rfs-modules
-  - rfs-firmware

configs/init

@@ -1,106 +0,0 @@
-#!/bin/sh -x
-# Alpine-based Zero-OS Init Script
-# Maintains identical flow to original busybox version
-
-echo ""
-echo "============================================"
-echo "==       ZERO-OS ALPINE INITRAMFS        =="
-echo "============================================"
-
-echo "[+] creating ram filesystem"
-target="/mnt/root"
-mkdir -p $target
-mount -t proc proc /proc
-mount -t sysfs sysfs /sys
-mount -t tmpfs tmpfs /mnt/root -o size=1024M
-mount -t devtmpfs devtmpfs /dev
-
-echo "[+] building ram filesystem"
-
-# Copy Alpine filesystem to tmpfs (same as original)
-echo "  copying /bin..."
-cp -ar /bin $target
-echo "  copying /etc..."
-cp -ar /etc $target
-echo "  copying /lib..."
-cp -ar /lib* $target
-echo "  copying /usr..."
-cp -ar /usr $target
-echo "  copying /root..."
-cp -ar /root $target
-echo "  copying /sbin..."
-cp -ar /sbin $target
-echo "  copying /tmp..."
-cp -ar /tmp $target
-echo "  copying /var..."
-cp -ar /var $target
-echo "  copying /run..."
-cp -ar /run $target
-
-# Create essential directories
-mkdir -p $target/dev
-mkdir -p $target/sys
-mkdir -p $target/proc
-mkdir -p $target/mnt
-
-# Mount filesystems in tmpfs
-mount -t proc proc $target/proc
-mount -t sysfs sysfs $target/sys
-mount -t devtmpfs devtmpfs $target/dev
-
-# Mount devpts for terminals
-mkdir -p $target/dev/pts
-mount -t devpts devpts $target/dev/pts
-
-echo "[+] setting environment"
-export PATH
-
-echo "[+] probing drivers"
-# Use Alpine's udev instead of busybox udevadm
-if [ -x /sbin/udevd ]; then
-    echo "  starting udevd..."
-    udevd --daemon
-    
-    echo "  triggering device discovery..."
-    udevadm trigger --action=add --type=subsystems
-    udevadm trigger --action=add --type=devices
-    udevadm settle
-    
-    echo "  stopping udevd..."
-    kill $(pidof udevd) || true
-else
-    echo "  warning: udevd not found, skipping hardware detection"
-fi
-
-echo "[+] loading essential drivers"
-# Load core drivers for storage and network
-modprobe btrfs 2>/dev/null || true
-modprobe fuse 2>/dev/null || true
-modprobe overlay 2>/dev/null || true
-
-# Load storage drivers
-modprobe ahci 2>/dev/null || true
-modprobe nvme 2>/dev/null || true
-modprobe virtio_blk 2>/dev/null || true
-modprobe virtio_scsi 2>/dev/null || true
-
-# Load network drivers  
-modprobe virtio_net 2>/dev/null || true
-modprobe e1000 2>/dev/null || true
-modprobe e1000e 2>/dev/null || true
-
-# Unmount init filesystems
-umount /proc 2>/dev/null || true
-umount /sys 2>/dev/null || true
-
-echo "[+] checking for debug files"
-if [ -e /init-debug ]; then
-    echo "  executing debug script..."
-    sh /init-debug
-fi
-
-echo "[+] switching root"
-echo "  exec switch_root /mnt/root /sbin/zinit init"
-exec switch_root /mnt/root /sbin/zinit -d init
-
-## 

configs/modules-essential.list

@@ -1,59 +0,0 @@
-# Essential kernel modules for Zero-OS Alpine initramfs
-# This file contains a curated list of essential modules for network and storage functionality
-# Comments are supported (lines starting with #)
-
-# Network drivers - Intel
-e1000
-e1000e
-igb
-ixgbe
-i40e
-ice
-
-# Network drivers - Realtek
-r8169
-8139too
-8139cp
-
-# Network drivers - Broadcom
-bnx2
-bnx2x
-tg3
-b44
-
-# Network drivers - Atheros
-atl1
-atl1e
-atl1c
-alx
-
-# VirtIO drivers
-virtio_net
-virtio_scsi
-virtio_blk
-virtio_pci
-
-# Tunnel and container support
-tun
-overlay
-
-# Storage subsystem (essential only)
-scsi_mod
-sd_mod
-
-# Control Groups (cgroups v1 and v2) - essential for container management
-cgroup_pids
-cgroup_freezer
-cgroup_perf_event
-cgroup_device
-cgroup_cpuset
-cgroup_bpf
-cgroup_debug
-memcg
-blkio_cgroup
-cpu_cgroup
-cpuacct
-hugetlb_cgroup
-net_cls_cgroup
-net_prio_cgroup
-devices_cgroup

configs/packages-minimal.txt

@@ -1,46 +0,0 @@
-# MINIMAL Alpine packages for Zero-OS embedded initramfs
-# Target: ~50MB total (not 700MB!)
-
-# Core system (essential only)
-alpine-baselayout
-busybox
-musl
-
-# Module loading & hardware detection
-eudev
-eudev-hwids
-eudev-libs
-eudev-netifnames
-kmod
-
-# Console/terminal management
-util-linux
-
-# Essential networking (for Zero-OS connectivity)
-iproute2
-ethtool
-
-# Filesystem support (minimal)
-btrfs-progs
-dosfstools
-
-# Essential libraries only
-zlib
-
-# Network utilities (minimal)
-dhcpcd
-tcpdump
-bmon
-
-# Random number generation (for crypto/security)
-haveged
-
-# SSH access and terminal multiplexer
-openssh-server
-zellij
-
-
-# Essential debugging and monitoring tools included
-# NO development tools, NO curl/wget, NO python, NO redis
-# NO massive linux-firmware package
-# Other tools will be loaded from RFS after network connectivity

configs/sources.conf

@@ -1,10 +0,0 @@
-# sources.conf - Components to download and build for initramfs
-# Format: TYPE:NAME:URL:VERSION:BUILD_FUNCTION[:EXTRA_OPTIONS]
-
-# Git repositories to clone and build
-git:zinit:https://github.com/threefoldtech/zinit:master:build_zinit
-git:mycelium:https://github.com/threefoldtech/mycelium:0.6.1:build_mycelium
-git:rfs:https://github.com/threefoldtech/rfs:development:build_rfs
-
-# Pre-built releases to download
-release:corex:https://github.com/threefoldtech/corex/releases/download/2.1.4/corex-2.1.4-amd64-linux-static:2.1.4:install_corex:rename=corex

configs/zinit/cgroup.yaml

@@ -1,2 +0,0 @@
-exec: sh /etc/zinit/init/cgroup.sh
-oneshot: true

configs/zinit/console.yaml

@@ -1,2 +0,0 @@
-exec: /sbin/getty -L 9600 console
-restart: always

configs/zinit/depmod.yaml

@@ -1 +0,0 @@
-exec: depmod -a

configs/zinit/getty.yaml

@@ -1,2 +0,0 @@
-exec: /sbin/getty -L 115200 ttyS0 vt100
-restart: always

configs/zinit/gettyconsole.yaml

@@ -1,2 +0,0 @@
-exec: /sbin/getty console linux
-restart: always

configs/zinit/haveged.yaml

@@ -1,2 +0,0 @@
-exec: haveged -w 1024 -d 32 -i 32 -v 1
-oneshot: true

configs/zinit/init/ashloging.sh

@@ -1,6 +0,0 @@
-#!/bin/bash
-
-echo "start ash terminal"
-while true; do
-    getty -l /bin/ash -n 19200 tty2
-done

configs/zinit/init/cgroup.sh

@@ -1,10 +0,0 @@
-set -x
-
-mount -t tmpfs cgroup_root /sys/fs/cgroup
-
-subsys="pids cpuset cpu cpuacct blkio memory devices freezer net_cls perf_event net_prio hugetlb"
-
-for sys in $subsys; do
-    mkdir -p /sys/fs/cgroup/$sys
-    mount -t cgroup $sys -o $sys /sys/fs/cgroup/$sys/
-done

configs/zinit/init/modprobe.sh

@@ -1,10 +0,0 @@
-#!/bin/bash
-
-modprobe fuse
-modprobe btrfs
-modprobe tun
-modprobe br_netfilter
-
-echo never > /sys/kernel/mm/transparent_hugepage/enabled
-
-ulimit -n 524288

configs/zinit/init/ntpd.sh

@@ -1,10 +0,0 @@
-#!/bin/sh
-
-ntp_flags=$(grep -o 'ntp=.*' /proc/cmdline | sed 's/^ntp=//')
-
-params=""
-if [ -n "$ntp_flags" ]; then
-  params=$(echo "-p $ntp_flags" | sed s/,/' -p '/g)
-fi
-
-exec ntpd -n $params

configs/zinit/init/routing.sh

@@ -1,4 +0,0 @@
-#!/bin/bash
-
-echo "Enable ip forwarding"
-echo 1 > /proc/sys/net/ipv4/ip_forward

configs/zinit/init/shm.sh

@@ -1,3 +0,0 @@
-#!/bin/sh
-mkdir /dev/shm
-mount -t tmpfs shm /dev/shm 

configs/zinit/init/sshd-setup.sh

@@ -1,15 +0,0 @@
-#!/bin/ash
-if [ -f /etc/ssh/ssh_host_rsa_key ]; then
-    # ensure existing file permissions
-    chown root:root /etc/ssh/ssh_host_*
-    chmod 600 /etc/ssh/ssh_host_*
-    exit 0
-fi
-
-echo "Setting up sshd"
-mkdir -p /run/sshd
-
-ssh-keygen -f /etc/ssh/ssh_host_rsa_key -N '' -t rsa
-ssh-keygen -f /etc/ssh/ssh_host_dsa_key -N '' -t dsa
-ssh-keygen -f /etc/ssh/ssh_host_ecdsa_key -N '' -t ecdsa -b 521
-ssh-keygen -f /etc/ssh/ssh_host_ed25519_key -N '' -t ed25519

configs/zinit/init/udev.sh

@@ -1,4 +0,0 @@
-#!/bin/sh
-
-udevadm trigger --action=add
-udevadm settle

configs/zinit/lo.yaml

@@ -1,2 +0,0 @@
-exec: ip l set lo up
-oneshot: true

configs/zinit/local-modprobe.yaml

@@ -1,2 +0,0 @@
-exec: sh /etc/zinit/init/modprobe.sh
-oneshot: true

configs/zinit/mycelium.yaml

@@ -1,6 +0,0 @@
-exec: /usr/bin/mycelium --key-file /tmp/mycelium_priv_key.bin
-  --tun-name my0 --silent --peers tcp://188.40.132.242:9651 tcp://136.243.47.186:9651
-  tcp://185.69.166.7:9651 tcp://185.69.166.8:9651 tcp://65.21.231.58:9651 tcp://65.109.18.113:9651
-  tcp://209.159.146.190:9651 tcp://5.78.122.16:9651 tcp://5.223.43.251:9651 tcp://142.93.217.194:9651
-after:
-  - network

configs/zinit/network.yaml

@@ -1,5 +0,0 @@
-exec: dhcpcd eth0
-after:
-  - depmod
-  - udevd
-  - udev-trigger

configs/zinit/ntp.yaml

@@ -1,3 +0,0 @@
-exec: sh /etc/zinit/init/ntpd.sh
-after:
-  - network

configs/zinit/routing.yaml

@@ -1,2 +0,0 @@
-exec: sh /etc/zinit/init/routing.sh
-oneshot: true

configs/zinit/shm.yaml

@@ -1,2 +0,0 @@
-exec: /etc/zinit/init/shm.sh
-oneshot: true

configs/zinit/sshd-setup.yaml

@@ -1,2 +0,0 @@
-exec: sh /etc/zinit/init/sshd-setup.sh
-oneshot: true

configs/zinit/sshd.yaml

@@ -1,3 +0,0 @@
-exec: /usr/sbin/sshd -D -e
-after:
-    - sshd-setup

configs/zinit/udev-trigger.yaml

@@ -1,6 +0,0 @@
-exec: sh /etc/zinit/init/udev.sh
-oneshot: true
-after:
-  - depmod
-  - udevmon
-  - udevd

configs/zinit/udevd.yaml

@@ -1 +0,0 @@
-exec: udevd

configs/zinit/udevmon.yaml

@@ -1 +0,0 @@
-exec: udevadm monitor

docs/NOTES.md

@@ -86,7 +86,7 @@ Initramfs Assembly – Key Functions
 - Components copy: [bash.initramfs_copy_components()](scripts/lib/initramfs.sh:101)
   - Installs built components (zinit/rfs/mycelium/corex) into proper locations, strips/UPX where applicable.
 - Modules setup: [bash.initramfs_setup_modules()](scripts/lib/initramfs.sh:229)
-  - Reads [config/modules.conf](config/modules.conf), resolves deps via [bash.initramfs_resolve_module_dependencies()](scripts/lib/initramfs.sh:318), generates stage1 list with firmware correlation.
+  - Reads [config/modules.conf](config/modules.conf), resolves deps via [bash.initramfs_resolve_module_dependencies()](scripts/lib/initramfs.sh:318), generates stage1 list (firmware hints in modules.conf are ignored; firmware.conf is authoritative).
 - Create module scripts: [bash.initramfs_create_module_scripts()](scripts/lib/initramfs.sh:427)
   - Writes /etc/zinit/init/stage1-modules.sh and stage2-modules.sh for zinit to load modules.
 - Binary size optimization: [bash.initramfs_strip_and_upx()](scripts/lib/initramfs.sh:491)
@@ -110,10 +110,19 @@ RFS Flists (modules/firmware)
 - Packing scripts:
   - Modules: [bash.pack-modules.sh](scripts/rfs/pack-modules.sh:1)
   - Firmware: [bash.pack-firmware.sh](scripts/rfs/pack-firmware.sh:1)
+- Firmware policy:
+  - For initramfs: [config/firmware.conf](config/firmware.conf) is the single source of truth for preinstalled firmware; modules.conf hints are ignored.
+  - For RFS: install all Alpine linux-firmware* packages into the build container and pack from /lib/firmware (full set for runtime).
 - Integrated in stage_rfs_flists:
   - Embeds /etc/rfs/modules-<FULL_KERNEL_VERSION>.fl
   - Embeds /etc/rfs/firmware-latest.fl (or tagged by FIRMWARE_TAG)
   - See [bash.main_build_process() — stage_rfs_flists](scripts/build.sh:298)
+- Runtime mount/readiness:
+  - Firmware flist mounts over /lib/firmware (overmount hides any initramfs firmware).
+  - Modules flist mounts at /lib/modules/$(uname -r).
+  - Init scripts probe BASE_URL reachability (accepts FLISTS_BASE_URL or FLIST_BASE_URL) and wait for HTTP(S) before fetching:
+    - Firmware: [sh.firmware.sh](config/zinit/init/firmware.sh:1)
+    - Modules: [sh.modules.sh](config/zinit/init/modules.sh:1)
 
 Branding Behavior (Passwordless Root, motd/issue)
 - Finalization hook: [bash.initramfs_finalize_customization()](scripts/lib/initramfs.sh:575)
@@ -126,10 +135,12 @@ Branding Behavior (Passwordless Root, motd/issue)
   - Branding also updates /etc/motd and /etc/issue to Zero-OS.
 
 Console and getty
+- Early keyboard and debug:
+  - [config/init](config/init) preloads input/HID and USB HCD modules (i8042, atkbd, usbhid, hid, hid_generic, evdev, xhci/ehci/ohci/uhci) so console input works before zinit/rfs.
+  - Kernel cmdline initdebug=true opens an early interactive shell; if /init-debug exists and is executable, it runs preferentially.
 - Serial and console getty configs (zinit service YAML):
-  - [config/zinit/getty.yaml](config/zinit/getty.yaml)
+  - [config/zinit/getty-tty1.yaml](config/zinit/getty-tty1.yaml)
-  - [config/zinit/gettyconsole.yaml](config/zinit/gettyconsole.yaml)
+  - [config/zinit/getty-console.yaml](config/zinit/getty-console.yaml)
-  - [config/zinit/console.yaml](config/zinit/console.yaml)
 - Optional ash login loop (not enabled unless referenced):
   - [bash.ashloging.sh](config/zinit/init/ashloging.sh:1)
 
@@ -156,14 +167,23 @@ How to Verify Passwordless Root
 
 Stage System and Incremental Rebuilds
 - Stage markers stored in .build-stages/ (one file per stage).
-- To minimally rebuild:
+- Minimal rebuild helper (host or container):
-  - Remove relevant .done files, e.g.:
+  - [scripts/rebuild-after-zinit.sh](scripts/rebuild-after-zinit.sh) clears only: modules_setup, modules_copy, init_script, zinit_setup, validation, initramfs_create, initramfs_test (kernel_build only with --with-kernel; kernel_modules only with --refresh-container-mods).
-    - initramfs_create.done initramfs_test.done validation.done
+  - Flags:
+    - --with-kernel (also rebuild kernel; ensures cpio is recreated right before embedding)
+    - --refresh-container-mods (rebuild container /lib/modules for fresh containers)
+    - --verify-only (report changed files and stage status; no rebuild)
+  - Shows stage status before/after marker removal; no --rebuild-from is passed by default (relies on markers only).
+- Manual minimal rebuild:
+  - Remove relevant .done files, e.g.: initramfs_create.done initramfs_test.done validation.done
   - Rerun: DEBUG=1 ./scripts/build.sh --skip-tests
 - Show status:
   - ./scripts/build.sh --show-stages
 
 Key Decisions (current)
+- Firmware selection for initramfs comes exclusively from [config/firmware.conf](config/firmware.conf); firmware hints in modules.conf are ignored to avoid duplication/mismatch.
+- Runtime firmware flist overmounts /lib/firmware after network readiness; init scripts wait for FLISTS_BASE_URL/FLIST_BASE_URL HTTP reachability before fetching.
+- Early keyboard and debug shell added to [config/init](config/init) as described above.
 - Branding enforces passwordless root via passwd -d -R inside initramfs finalization, avoiding direct edits of passwd/shadow files.
 - Directory paths normalized to absolute after loading config to avoid CWD-sensitive behavior.
 - Container image contains shadow suite to ensure passwd/chpasswd availability; perl removed.
@@ -172,11 +192,11 @@ File Pointers (quick jump)
 - Orchestrator: [scripts/build.sh](scripts/build.sh)
 - Common and config loading: [bash.common.sh](scripts/lib/common.sh:1)
 - Finalization hook: [bash.initramfs_finalize_customization()](scripts/lib/initramfs.sh:575)
-- Passwordless deletion: [bash.initramfs_finalize_customization()](scripts/lib/initramfs.sh:592)
 - Validation entry: [bash.initramfs_validate()](scripts/lib/initramfs.sh:799)
 - CPIO creation: [bash.initramfs_create_cpio()](scripts/lib/initramfs.sh:688)
 - Kernel embed config: [bash.kernel_modify_config_for_initramfs()](scripts/lib/kernel.sh:130)
 - RFS packers: [bash.pack-modules.sh](scripts/rfs/pack-modules.sh:1), [bash.pack-firmware.sh](scripts/rfs/pack-firmware.sh:1)
+- USB creator: [scripts/make-grub-usb.sh](scripts/make-grub-usb.sh)
 
 Change Log
 - 2025-09-09:

docs/PROMPT.md

@@ -34,6 +34,8 @@ Repository map (jump-points)
 - RFS flists tooling:
   - Modules packer: [bash.pack-modules.sh](scripts/rfs/pack-modules.sh:1)
   - Firmware packer: [bash.pack-firmware.sh](scripts/rfs/pack-firmware.sh:1)
+- Boot media utility:
+  - GRUB USB creator: [scripts/make-grub-usb.sh](scripts/make-grub-usb.sh)
 
 High-priority behaviors and policies
 1) Branding passwordless root (shadow-aware)
@@ -53,18 +55,20 @@ High-priority behaviors and policies
 - Pre-CPIO essential check includes “home”:
   - [bash.initramfs_create_cpio()](scripts/lib/initramfs.sh:680)
 
-4) Remote flist fallback (modules + firmware)
+4) Remote flist fallback + readiness (modules + firmware)
 - When local manifests are missing, fetch from zos.grid.tf and mount via rfs:
-  - Firmware fallback: [sh.firmware.sh](config/zinit/init/firmware.sh:1)
+  - Firmware: [sh.firmware.sh](config/zinit/init/firmware.sh:1)
-    - Default BASE_URL: https://zos.grid.tf/store/flists
+    - BASE_URL from FLISTS_BASE_URL (or FLIST_BASE_URL alias), default https://zos.grid.tf/store/flists
-    - Fetch path: ${BASE_URL}/firmware-latest.fl to /etc/rfs/firmware-latest.fl
+    - Probes BASE_URL for HTTP(S) readiness (wget --spider) before fetching firmware-latest.fl
-  - Modules fallback: [sh.modules.sh](config/zinit/init/modules.sh:1)
+    - Fetch path: ${BASE_URL%/}/firmware-latest.fl to /etc/rfs/firmware-latest.fl
-    - Fetch path: ${BASE_URL}/modules-$(uname -r)-Zero-OS.fl to /etc/rfs/modules-$(uname -r).fl
+  - Modules: [sh.modules.sh](config/zinit/init/modules.sh:1)
-  - Env overrides:
+    - BASE_URL from FLISTS_BASE_URL (or FLIST_BASE_URL alias)
+    - Probes BASE_URL for HTTP(S) readiness before fetching modules-$(uname -r)-Zero-OS.fl
+- Env overrides:
   - FIRMWARE_FLIST, MODULES_FLIST: use local file if provided
   - RFS_BIN: defaults to rfs
-    - FLISTS_BASE_URL: overrides base URL
+  - FLISTS_BASE_URL or FLIST_BASE_URL: override base URL
-  - wget is available (initramfs includes it); scripts prefer wget, fallback to busybox wget if needed.
+- wget is available (initramfs includes it); scripts prefer wget, fallback to busybox wget if needed.
 
 5) Incremental build guards
 - Kernel build now defaults INITRAMFS_ARCHIVE if unset (fix for unbound var on incremental runs):
@@ -72,6 +76,12 @@ High-priority behaviors and policies
 - Initramfs test stage already guards INITRAMFS_ARCHIVE:
   - [bash.stage_initramfs_test()](scripts/build.sh:385)
 
+6) Early keyboard input and debug shell
+- Early HID/input and USB HCD modules are preloaded before zinit to ensure console usability:
+  - [config.init](config/init:80)
+- Debug hook: kernel cmdline initdebug=true runs /init-debug if present or drops to a shell:
+  - [config.init](config/init:115)
+
 Flags and config
 - Config file: [config/build.conf](config/build.conf)
 - Branding flags:
@@ -85,6 +95,9 @@ Flags and config
   - COMPONENTS_DIR="components"
   - KERNEL_DIR="kernel"
   - DIST_DIR="dist"
+- Firmware policies:
+  - Initramfs: [config/firmware.conf](config/firmware.conf) is authoritative; modules.conf firmware hints are ignored.
+  - RFS: full Alpine firmware set is installed into container and packed from /lib/firmware (see [bash.pack-firmware.sh](scripts/rfs/pack-firmware.sh:1)).
 - Firmware flist naming tag:
   - FIRMWARE_TAG (env > config > “latest”)
 - Container image tools (podman rootless OK) defined by [Dockerfile](Dockerfile):
@@ -113,7 +126,7 @@ Common tasks and commands
 - Show stage status:
   - ./scripts/build.sh --show-stages
 
-Checklists
+Checklists and helpers
 
 A) Diagnose “passwordless root not working”
 - Confirm branding flags are loaded:
@@ -130,17 +143,34 @@ B) Fix “Initramfs directory not found: initramfs (resolved: /workspace/kernel/
 - Confirm validation prints “Validation debug:” with resolved absolute path:
   - [bash.initramfs_validate()](scripts/lib/initramfs.sh:799)
 
-C) INITRAMFS_ARCHIVE unbound during kernel build stage
+C) Minimal rebuild after zinit/init/modules.conf changes
+- Use the helper (works from host or container):
+  - scripts/rebuild-after-zinit.sh
+    - Defaults: initramfs-only; clears only modules_setup, modules_copy, init_script, zinit_setup, validation, initramfs_create, initramfs_test
+    - Flags:
+      - --with-kernel: also rebuild kernel; cpio is recreated immediately before embedding
+      - --refresh-container-mods: rebuild container /lib/modules for fresh containers
+      - --verify-only: report changed files and stage status; no rebuild
+  - Stage status is printed before/after marker removal; the helper avoids --rebuild-from by default to prevent running early stages.
+- Manual fallback:
+  - rm -f .build-stages/initramfs_create.done .build-stages/initramfs_test.done .build-stages/validation.done
+  - DEBUG=1 ./scripts/build.sh --skip-tests
+
+D) INITRAMFS_ARCHIVE unbound during kernel build stage
 - stage_kernel_build now defaults INITRAMFS_ARCHIVE if unset:
   - [bash.stage_kernel_build()](scripts/build.sh:398)
 - If error persists, ensure stage_initramfs_create ran or that defaulting logic sees dist/initramfs.cpio.xz.
 
-D) Modules/firmware not found by rfs init scripts
+E) Modules/firmware not found by rfs init scripts
-- Confirm local manifests under /etc/rfs or remote fallback working:
+- Confirm local manifests under /etc/rfs or remote fallback:
   - Firmware: [sh.firmware.sh](config/zinit/init/firmware.sh:1)
   - Modules: [sh.modules.sh](config/zinit/init/modules.sh:1)
+- For remote:
+  - Set FLISTS_BASE_URL or FLIST_BASE_URL; default is https://zos.grid.tf/store/flists
+  - Scripts probe BASE_URL readiness (wget --spider) before fetch
+  - Firmware target is /lib/firmware; modules target is /lib/modules/$(uname -r)
 - Confirm uname -r matches remote naming “modules-$(uname -r)-Zero-OS.fl”
-- Confirm wget present (it is in initramfs), or busybox fallback.
+- Confirm wget present (or busybox wget)
 
 Project conventions
 - Edit policy:
@@ -157,8 +187,9 @@ Key files to keep in sync with behavior decisions
 - Validation diagnostics: [bash.initramfs_validate()](scripts/lib/initramfs.sh:799)
 - Archive creation (pre-CPIO checks): [bash.initramfs_create_cpio()](scripts/lib/initramfs.sh:688)
 - Path normalization after config: [bash.common.sh](scripts/lib/common.sh:236)
-- Modules/firmware remote fallback: [sh.modules.sh](config/zinit/init/modules.sh:1), [sh.firmware.sh](config/zinit/init/firmware.sh:1)
+- Modules/firmware remote fallback + readiness: [sh.modules.sh](config/zinit/init/modules.sh:1), [sh.firmware.sh](config/zinit/init/firmware.sh:1)
 - Kernel stage defaulting for archive: [bash.stage_kernel_build()](scripts/build.sh:398)
+- GRUB USB creator: [scripts/make-grub-usb.sh](scripts/make-grub-usb.sh)
 - Operational notes: [docs/NOTES.md](docs/NOTES.md)
 
 When in doubt

docs/review-rfs-integration.md

@@ -124,7 +124,7 @@ Directory: scripts/rfs
 ## Future runtime units (deferred)
 
 Will be added as new zinit units once flist generation is validated:
-- Mount firmware flist read-only at /usr/lib/firmware
+- Mount firmware flist read-only at /lib/firmware (overmount to hide initramfs firmware beneath)
 - Mount modules flist read-only at /lib/modules/<FULL_VERSION>
 - Run depmod -a <FULL_VERSION>
 - Run udev coldplug sequence (reload, trigger add, settle)

initramfs/etc/apk/world

@@ -20,10 +20,13 @@ iproute2
 kmod
 libc-utils
 linux-firmware-bnx2
+linux-firmware-bnx2x
 linux-firmware-e100
 linux-firmware-intel
 linux-firmware-qlogic
 linux-firmware-realtek
+linux-firmware-rtl_nic
+linux-firmware-tigon
 musl
 nftables
 openssh-server

initramfs/etc/shadow

@@ -1,4 +1,4 @@
-root::20349:0:::::
+root::20354:0:::::
 bin:!::0:::::
 daemon:!::0:::::
 lp:!::0:::::

scripts/lib/alpine.sh

@@ -395,26 +395,19 @@ function alpine_install_firmware() {
     
     section_header "Installing Required Firmware Packages (Selective)"
     
-    # Use smart firmware selection from module analysis if available
+    # Policy: firmware.conf is the authoritative source for initramfs firmware
     local firmware_packages=()
     
-    if [[ -n "${REQUIRED_FIRMWARE_PACKAGES:-}" ]]; then
-        log_info "Using intelligent firmware selection based on COPIED modules only"
-        read -ra firmware_packages <<< "$REQUIRED_FIRMWARE_PACKAGES"
-        
-        log_info "Required firmware packages (${#firmware_packages[@]}):"
-        for package in "${firmware_packages[@]}"; do
-            log_info "  ✓ ${package}"
-        done
-    else
-        log_info "Falling back to firmware configuration file"
-        
     if [[ ! -f "$firmware_conf" ]]; then
-            log_warn "No firmware configuration found and no module requirements"
+        log_warn "Firmware configuration not found: ${firmware_conf}; skipping firmware installation to initramfs"
-            log_info "Skipping firmware installation"
         return 0
     fi
 
+    # Ignore any REQUIRED_FIRMWARE_PACKAGES hints to avoid duplication/mismatch with modules.conf
+    if [[ -n "${REQUIRED_FIRMWARE_PACKAGES:-}" ]]; then
+        log_info "Firmware selection: ignoring REQUIRED_FIRMWARE_PACKAGES; using ${firmware_conf} as authoritative source"
+    fi
+
     # Read firmware packages from config (excluding comments and empty lines)
     while IFS=: read -r package description; do
         # Skip comments and empty lines
@@ -431,7 +424,6 @@ function alpine_install_firmware() {
             log_info "  - ${package}: ${description}"
         fi
     done < "$firmware_conf"
-    fi
     
     if [[ ${#firmware_packages[@]} -eq 0 ]]; then
         log_warn "No firmware packages to install"

scripts/lib/docker.sh

@@ -56,7 +56,7 @@ function docker_build_container() {
     fi
     
     log_info "Building container image: ${tag}"
-    safe_execute ${CONTAINER_RUNTIME} build -t "${tag}" -f "${dockerfile_path}" "${PROJECT_ROOT}"
+    ${CONTAINER_RUNTIME} build -t "${tag}" -f "${dockerfile_path}" "${PROJECT_ROOT}"
     
     log_info "Container image built successfully: ${tag}"
 }

scripts/lib/initramfs.sh

@@ -250,16 +250,9 @@ function initramfs_setup_modules() {
     local stage1_modules=()
     local stage1_firmware=()
     
-    while IFS=: read -r stage module firmware_line; do
+    while IFS=: read -r stage module _ignored_fw; do
         if [[ "$stage" == "stage1" && -n "$module" ]]; then
             stage1_modules+=("$module")
-            # Extract firmware package name (before any comment)
-            local firmware=$(echo "$firmware_line" | sed 's/[[:space:]]*#.*//' | tr -d ' ')
-            if [[ -n "$firmware" && "$firmware" != "none" ]]; then
-                stage1_firmware+=("$firmware")
-                required_firmware+=("$firmware")
-                log_debug "Module $module requires firmware: $firmware"
-            fi
         fi
     done < <(grep "^stage1:" "$modules_conf")
     
@@ -286,32 +279,32 @@ function initramfs_setup_modules() {
     local stage2_with_deps=()
     
     # Create firmware requirements list (remove duplicates)
-    local unique_firmware=($(printf '%s\n' "${required_firmware[@]}" | sort -u))
+    # Firmware selection policy: use config/firmware.conf as the authoritative source.
-    if [[ ${#unique_firmware[@]} -gt 0 ]]; then
+    # Ignore firmware hints in modules.conf (third column) to avoid duplication/mismatch.
-        printf '%s\n' "${unique_firmware[@]}" > "${modules_dir}/required-firmware.list"
+    if [[ -f "${PROJECT_ROOT}/config/firmware.conf" ]]; then
-        log_info "Created firmware requirements list: ${#unique_firmware[@]} packages"
+        log_info "Firmware selection: using config/firmware.conf (ignoring modules.conf firmware hints)"
-        for fw in "${unique_firmware[@]}"; do
-            log_info "  Required firmware: $fw"
-        done
-        
-        # Export for use by firmware installation
-        export REQUIRED_FIRMWARE_PACKAGES="${unique_firmware[*]}"
     else
-        log_info "No firmware packages required"
+        log_warn "Firmware selection: config/firmware.conf not found; no firmware will be installed into initramfs"
-        export REQUIRED_FIRMWARE_PACKAGES=""
     fi
+    # Remove any stale list created by previous versions
+    rm -f "${modules_dir}/required-firmware.list" 2>/dev/null || true
+    # Do NOT export REQUIRED_FIRMWARE_PACKAGES anymore; alpine_install_firmware reads the config file directly.
     
     # Create module loading scripts
     initramfs_create_module_scripts "$initramfs_dir" "$kernel_version"
     
     # Report final counts
     local stage1_count=${#stage1_with_deps[@]}
-    local firmware_count=${#unique_firmware[@]}
+    # Count firmware entries from authoritative firmware.conf (non-empty, non-comment lines)
+    local firmware_count=0
+    if [[ -f "${PROJECT_ROOT}/config/firmware.conf" ]]; then
+        firmware_count=$(grep -v '^[[:space:]]*#' "${PROJECT_ROOT}/config/firmware.conf" | sed '/^[[:space:]]*$/d' | wc -l | tr -d ' ')
+    fi
     
     log_info "Module configuration complete:"
     log_info "  Stage1 (critical + deps): ${stage1_count} modules"
     log_info "  Stage2: disabled (only using stage1)"
-    log_info "  Required firmware packages: ${firmware_count}"
+    log_info "  Firmware packages (from firmware.conf): ${firmware_count}"
     log_info "  Total modules: ${stage1_count}"
 }
 
@@ -631,6 +624,17 @@ EOF
         log_info "Branding disabled: leaving /etc/motd, /etc/issue and root password unchanged"
     fi
 
+    # Write a unique build stamp to verify runtime image freshness
+    # Allows confirming that the booted VM uses the latest embedded initramfs
+    local _rand=""
+    if command_exists "openssl"; then _rand=$(openssl rand -hex 6 2>/dev/null || true); fi
+    local _build_id="ZOS-BUILD $(date -u +%Y-%m-%dT%H:%M:%SZ) ${_rand}"
+    # Write via tee to ensure creation + visible logging, avoid shell redirection edge cases
+    safe_mkdir "${initramfs_dir}/etc"
+    printf "%s\n" "${_build_id}" | tee "${initramfs_dir}/etc/zero-os-build-id" >/dev/null
+    safe_execute chmod 644 "${initramfs_dir}/etc/zero-os-build-id"
+    log_info "Build ID: ${_build_id} (written to /etc/zero-os-build-id)"
+
     # Ensure essential Linux filesystem directories exist (defensive), including /home
     # Some earlier stages or cleanups may have run in previous builds; enforce presence now.
     log_info "Ensuring essential directories exist (including /home)"
@@ -1070,8 +1074,39 @@ function initramfs_copy_resolved_modules() {
     for module in "${all_modules[@]}"; do
         local module_found=false
 
-        # Try to find module file
+        # Try to find module file with robust underscore/hyphen aliasing
-        local module_file=$(find "$container_modules_path" -name "${module}.ko*" -type f | head -1)
+        # modprobe treats '_' and '-' as equivalent, but our file search must do both.
+        local query="${module}"
+        local module_file=""
+
+        # 1) Exact match (as given)
+        module_file=$(find "$container_modules_path" -name "${query}.ko*" -type f | head -1)
+
+        # 2) Fallback: underscores -> hyphens (e.g., xhci_pci -> xhci-pci)
+        if [[ -z "$module_file" || ! -f "$module_file" ]]; then
+            local alt="${query//_/-}"
+            if [[ "$alt" != "$query" ]]; then
+                module_file=$(find "$container_modules_path" -name "${alt}.ko*" -type f | head -1)
+                if [[ -n "$module_file" && -f "$module_file" ]]; then
+                    log_info "Resolved module alias: ${query} -> ${alt} (hyphen)"
+                    query="$alt"
+                fi
+            fi
+        fi
+
+        # 3) Fallback: hyphens -> underscores (defensive; modinfo sometimes reports hyphen)
+        if [[ -z "$module_file" || ! -f "$module_file" ]]; then
+            local alt2="${query//-/_}"
+            if [[ "$alt2" != "$query" ]]; then
+                local mf2
+                mf2=$(find "$container_modules_path" -name "${alt2}.ko*" -type f | head -1)
+                if [[ -n "$mf2" && -f "$mf2" ]]; then
+                    log_info "Resolved module alias: ${query} -> ${alt2} (underscore)"
+                    query="$alt2"
+                    module_file="$mf2"
+                fi
+            fi
+        fi
 
         if [[ -n "$module_file" && -f "$module_file" ]]; then
             # Preserve directory structure
@@ -1081,13 +1116,13 @@ function initramfs_copy_resolved_modules() {
             safe_mkdir "$target_dir"
             safe_execute cp "$module_file" "${initramfs_modules_dir}/${rel_path}"
 
-            log_debug "Copied module: $module from $rel_path"
+            log_debug "Copied module: ${query} from ${rel_path}"
             ((copied_count++))
             module_found=true
         fi
 
         if [[ "$module_found" == "false" ]]; then
-            log_warn "Module not found in container: $module"
+            log_warn "Module not found in container (after alias fallbacks): ${module}"
             ((failed_count++))
         fi
     done

scripts/make-grub-usb.sh

@@ -0,0 +1,256 @@
+#!/usr/bin/env bash
+# Create a GRUB USB disk that boots on both BIOS (legacy) and UEFI.
+# It copies kernel (vmlinuz) and initramfs, installs GRUB for i386-pc and x86_64-efi,
+# and writes a minimal grub.cfg with optional kernel parameters.
+#
+# DANGEROUS: This script will repartition and format the target device (e.g., /dev/sdX).
+#
+# Usage:
+#   sudo scripts/make-grub-usb.sh /dev/sdX \
+#        --kernel dist/vmlinuz.efi \
+#        --initrd dist/initramfs.cpio.xz \
+#        --kparams "console=ttyS0 initdebug=true" \
+#        --label ZOSBOOT \
+#        --no-confirm
+#
+# Defaults (resolved relative to repo root):
+#   --kernel  dist/vmlinuz.efi
+#   --initrd  dist/initramfs.cpio.xz
+#   --label   ZOS
+#   --kparams ""  (none)
+#
+# Requirements on host:
+#   - grub-install (supports --target=i386-pc and --target=x86_64-efi)
+#   - parted, sfdisk (optional), dosfstools (mkfs.vfat), util-linux (lsblk, partprobe)
+#   - run as root
+#
+set -euo pipefail
+
+SCRIPT_DIR="$(cd "$(dirname "${BASH_SOURCE[0]}")" && pwd)"
+PROJECT_ROOT="$(dirname "$SCRIPT_DIR")"
+
+DEVICE="${1:-}"
+shift || true
+
+KERNEL="${PROJECT_ROOT}/dist/vmlinuz.efi"
+# Default: no separate initrd because initramfs is embedded in kernel. Enable with --with-initrd or --initrd.
+INITRD=""
+KPARAMS=""
+LABEL="ZOS"
+NO_CONFIRM=0
+ESP_SIZE_MB=512
+# Request including separate initrd
+WANT_INITRD=0
+
+error() { echo "[ERROR] $*" >&2; }
+info()  { echo "[INFO]  $*"; }
+warn()  { echo "[WARN]  $*"; }
+die()   { error "$*"; exit 1; }
+
+require_root() {
+  [[ "$EUID" -eq 0 ]] || die "This script must be run as root."
+}
+
+command_exists() { command -v "$1" &>/dev/null; }
+
+parse_args() {
+  while [[ $# -gt 0 ]]; do
+    case "$1" in
+      --kernel)
+        KERNEL="$(realpath -m "${2:-}")"; shift 2 ;;
+      --initrd)
+        INITRD="$(realpath -m "${2:-}")"; shift 2 ;;
+      --with-initrd)
+        WANT_INITRD=1; shift ;;
+      --kparams)
+        KPARAMS="${2:-}"; shift 2 ;;
+      --label)
+        LABEL="${2:-ZOS}"; shift 2 ;;
+      --no-confirm)
+        NO_CONFIRM=1; shift ;;
+      --esp-size-mb)
+        ESP_SIZE_MB="${2:-512}"; shift 2 ;;
+      -*)
+        die "Unknown option: $1" ;;
+      *)
+        die "Unexpected argument: $1" ;;
+    esac
+  done
+}
+
+confirm_dangerous() {
+  info "About to wipe and repartition device: ${DEVICE}"
+  lsblk -o NAME,SIZE,TYPE,MOUNTPOINT "${DEVICE}"
+  if [[ $NO_CONFIRM -eq 1 ]]; then
+    info "--no-confirm provided; proceeding without interactive confirmation"
+    return
+  fi
+  echo
+  read -r -p "Type the DEVICE path to CONFIRM (e.g., ${DEVICE}) or 'abort' to cancel: " ans
+  [[ "$ans" == "$DEVICE" ]] || die "Confirmation mismatch or aborted."
+}
+
+check_prereqs() {
+  command_exists parted      || die "parted not found"
+  command_exists mkfs.vfat   || die "mkfs.vfat (dosfstools) not found"
+  command_exists grub-install || die "grub-install not found"
+  command_exists lsblk       || die "lsblk not found"
+  command_exists partprobe   || die "partprobe not found"
+}
+
+resolve_defaults() {
+  [[ -b "$DEVICE" ]] || die "Device not found or not a block device: ${DEVICE}"
+  [[ -f "$KERNEL" ]] || die "Kernel file not found: ${KERNEL}"
+  if [[ $WANT_INITRD -eq 1 ]]; then
+    # If user asked for separate initrd but none specified, use default path
+    if [[ -z "${INITRD}" ]]; then
+      INITRD="${PROJECT_ROOT}/dist/initramfs.cpio.xz"
+    fi
+    [[ -f "$INITRD" ]] || die "Requested --with-initrd but initramfs not found: ${INITRD}"
+  else
+    # By default, no separate initrd (initramfs is embedded in kernel)
+    INITRD=""
+  fi
+}
+
+umount_partitions() {
+  info "Unmounting any mounted partitions of ${DEVICE}"
+  local kids
+  kids="$(lsblk -nr -o NAME "${DEVICE}" | tail -n +2 || true)"
+  if [[ -n "${kids}" ]]; then
+    while read -r name; do
+      [[ -z "$name" ]] && continue
+      local path="/dev/${name}"
+      if mountpoint -q -- "/dev/${name}" 2>/dev/null; then
+        umount -f "/dev/${name}" || true
+      fi
+      # also try mounts by path
+      local mp
+      mp="$(lsblk -nr -o MOUNTPOINT "$path" || true)"
+      if [[ -n "$mp" ]]; then
+        for m in $mp; do
+          [[ -n "$m" ]] && umount -f "$m" || true
+        done
+      fi
+    done <<< "${kids}"
+  fi
+}
+
+partition_device_gpt() {
+  info "Creating GPT with BIOS boot + ESP on ${DEVICE}"
+  # Create a new GPT
+  parted -s "${DEVICE}" mklabel gpt
+
+  # Create BIOS boot partition 1MiB..3MiB
+  parted -s "${DEVICE}" mkpart biosgrub 1MiB 3MiB
+  parted -s "${DEVICE}" set 1 bios_grub on
+
+  # Create ESP (FAT32) from 3MiB to 3MiB + ESP_SIZE_MB
+  local esp_end="$((3 + ESP_SIZE_MB))MiB"
+  parted -s "${DEVICE}" mkpart esp fat32 3MiB "${esp_end}"
+  parted -s "${DEVICE}" set 2 esp on
+
+  # Inform kernel
+  partprobe "${DEVICE}"
+  sleep 1
+}
+
+format_esp() {
+  local part="${DEVICE}2"
+  [[ -b "$part" ]] || die "ESP partition not found: ${part}"
+  info "Formatting ESP ${part} as FAT32 (label=${LABEL})"
+  mkfs.vfat -F32 -n "${LABEL}" "$part"
+}
+
+mount_esp() {
+  ESP_MNT="$(mktemp -d)"
+  info "Mounting ESP at ${ESP_MNT}"
+  mount "${DEVICE}2" "${ESP_MNT}"
+}
+
+install_grub() {
+  info "Installing GRUB (BIOS i386-pc) to ${DEVICE}"
+  grub-install --target=i386-pc --boot-directory="${ESP_MNT}/boot" --recheck "${DEVICE}"
+
+  info "Installing GRUB (UEFI x86_64-efi) to ESP"
+  mkdir -p "${ESP_MNT}/EFI/BOOT"
+  grub-install --target=x86_64-efi --efi-directory="${ESP_MNT}" --boot-directory="${ESP_MNT}/boot" --removable --recheck
+}
+
+copy_kernel_initrd() {
+  mkdir -p "${ESP_MNT}/boot"
+  info "Copying kernel to ESP /boot/vmlinuz"
+  cp -f "${KERNEL}" "${ESP_MNT}/boot/vmlinuz"
+  if [[ -n "${INITRD}" ]]; then
+    info "Copying initramfs to ESP /boot/initramfs.cpio.xz"
+    cp -f "${INITRD}" "${ESP_MNT}/boot/initramfs.cpio.xz"
+  fi
+}
+
+write_grub_cfg() {
+  local cfg="${ESP_MNT}/boot/grub/grub.cfg"
+  info "Writing GRUB config: ${cfg}"
+  mkdir -p "$(dirname "$cfg")"
+  cat > "$cfg" <<'EOF'
+set default=0
+set timeout=3
+
+if [ "${grub_platform}" = "efi" ]; then
+  set gfxpayload=keep
+fi
+
+menuentry "Zero-OS" {
+  linux /boot/vmlinuz __KPARAMS__
+__INITRD_LINE__
+}
+EOF
+
+  local initrd_line=""
+  if [[ -n "${INITRD}" ]]; then
+    initrd_line="  initrd /boot/initramfs.cpio.xz"
+  fi
+  # Substitute placeholders
+  sed -i \
+    -e "s|__KPARAMS__|${KPARAMS}|g" \
+    -e "s|__INITRD_LINE__|${initrd_line}|g" \
+    "$cfg"
+
+  # For removable media on UEFI, ensure fallback bootloader path exists
+  if [[ -f "/usr/lib/grub/x86_64-efi/monolithic/grubx64.efi" ]]; then
+    cp -f "/usr/lib/grub/x86_64-efi/monolithic/grubx64.efi" "${ESP_MNT}/EFI/BOOT/BOOTX64.EFI" || true
+  elif [[ -f "${ESP_MNT}/EFI/BOOT/grubx64.efi" ]]; then
+    cp -f "${ESP_MNT}/EFI/BOOT/grubx64.efi" "${ESP_MNT}/EFI/BOOT/BOOTX64.EFI" || true
+  fi
+}
+
+cleanup() {
+  set +e
+  if mountpoint -q "${ESP_MNT}" 2>/dev/null; then
+    info "Unmounting ESP ${ESP_MNT}"
+    umount "${ESP_MNT}"
+  fi
+  [[ -n "${ESP_MNT:-}" ]] && rmdir "${ESP_MNT}" 2>/dev/null || true
+}
+
+main() {
+  require_root
+  [[ -n "${DEVICE}" ]] || die "Usage: $0 /dev/sdX [--kernel path] [--initrd path] [--kparams \"...\"] [--label ZOS] [--no-confirm]"
+  parse_args "$@"
+  resolve_defaults
+  check_prereqs
+
+  confirm_dangerous
+  trap cleanup EXIT INT TERM
+
+  umount_partitions
+  partition_device_gpt
+  format_esp
+  mount_esp
+  install_grub
+  copy_kernel_initrd
+  write_grub_cfg
+
+  info "Done. You can now boot from the USB on BIOS and UEFI systems."
+}
+
+main "$@"

scripts/rebuild-after-zinit.sh

@@ -5,6 +5,7 @@
 #   scripts/rebuild-after-zinit.sh --run-tests              # include boot tests (still no kernel rebuild by default)
 #   scripts/rebuild-after-zinit.sh --with-kernel            # also rebuild kernel (re-embed updated initramfs)
 #   scripts/rebuild-after-zinit.sh --refresh-container-mods # rebuild container /lib/modules if missing (kernel modules stage)
+#   scripts/rebuild-after-zinit.sh --verify-only            # only report detected changes, do not rebuild
 #   scripts/rebuild-after-zinit.sh -- ...                   # pass extra args to build.sh
 
 set -euo pipefail
@@ -19,6 +20,7 @@ run_tests=0
 extra_args=()
 rebuild_kernel=0
 refresh_container_mods=0
+verify_only=0
 
 # Parse flags; pass through any remaining args to build.sh after --
 while [[ $# -gt 0 ]]; do
@@ -35,6 +37,10 @@ while [[ $# -gt 0 ]]; do
       refresh_container_mods=1
       shift
       ;;
+    --verify-only)
+      verify_only=1
+      shift
+      ;;
     --)
       shift
       extra_args=("$@")
@@ -51,6 +57,108 @@ done
 log "PROJECT_ROOT=${PROJECT_ROOT}"
 log "STAGES_DIR=${STAGES_DIR}"
 
+# Show current stage status before any changes (host-safe; does not require container)
+log "Stage status (before):"
+("${PROJECT_ROOT}/scripts/build.sh" --show-stages) || true
+
+# ------------------------------------------------------------
+# Container detection helper
+# ------------------------------------------------------------
+in_container() {
+  [[ -f /.dockerenv ]] || [[ -f /run/.containerenv ]] || grep -q 'container' /proc/1/cgroup 2>/dev/null
+}
+
+# ------------------------------------------------------------
+# Change detection (verify what changed since last archive build)
+# ------------------------------------------------------------
+marker_init="${STAGES_DIR}/initramfs_create.done"
+marker_time=0
+if [[ -f "$marker_init" ]]; then
+  marker_time=$(stat -c %Y "$marker_init" 2>/dev/null || echo 0)
+fi
+log "Detecting changes since last initramfs_create marker: ${marker_init:-<none>}"
+
+check_dir_changed() {
+  local path="$1"
+  local cutoff="$2"
+  local count
+  count=$(find "$path" -type f -printf '%T@ %p\n' 2>/dev/null | awk -v c="$cutoff" '$1 > c {n++} END {print n+0}')
+  echo "${count:-0}"
+}
+
+list_some_changes() {
+  local path="$1"
+  local cutoff="$2"
+  # list up to 5 example files
+  find "$path" -type f -printf '%T@ %p\n' 2>/dev/null | awk -v c="$cutoff" '$1 > c {print $2}' | head -n 5
+}
+
+zinit_dir="${PROJECT_ROOT}/config/zinit"
+init_file="${PROJECT_ROOT}/config/init"
+modules_conf="${PROJECT_ROOT}/config/modules.conf"
+
+zinit_changed=0
+init_changed=0
+modules_changed=0
+
+if [[ -d "$zinit_dir" ]]; then
+  zinit_changed=$(check_dir_changed "$zinit_dir" "$marker_time")
+fi
+if [[ -f "$init_file" ]]; then
+  if [[ $(stat -c %Y "$init_file" 2>/dev/null || echo 0) -gt $marker_time ]]; then init_changed=1; fi
+fi
+if [[ -f "$modules_conf" ]]; then
+  if [[ $(stat -c %Y "$modules_conf" 2>/dev/null || echo 0) -gt $marker_time ]]; then modules_changed=1; fi
+fi
+
+log "Changes since last archive:"
+log "  - config/zinit: ${zinit_changed} file(s) changed"
+if [[ "$zinit_changed" -gt 0 ]]; then
+  list_some_changes "$zinit_dir" "$marker_time" | sed 's/^/    * /' || true
+fi
+log "  - config/init: $([[ $init_changed -eq 1 ]] && echo changed || echo unchanged)"
+log "  - config/modules.conf: $([[ $modules_changed -eq 1 ]] && echo changed || echo unchanged)"
+
+if [[ "$verify_only" -eq 1 ]]; then
+  log "verify-only set; exiting without rebuild"
+  exit 0
+fi
+
+# ------------------------------------------------------------
+# Container /lib/modules/<FULL_VERSION> presence diagnostics
+# (we never clear kernel_modules unless --refresh-container-mods is given)
+# ------------------------------------------------------------
+compute_full_kver() {
+  # Read from configs without sourcing (safe in any shell)
+  local build_conf="${PROJECT_ROOT}/config/build.conf"
+  local kcfg="${PROJECT_ROOT}/config/kernel.config"
+  local base_ver=""
+  local localver=""
+  if [[ -f "$build_conf" ]]; then
+    base_ver="$(grep -E '^KERNEL_VERSION=' "$build_conf" | head -1 | cut -d= -f2 | tr -d '\"')"
+  fi
+  if [[ -f "$kcfg" ]]; then
+    localver="$(grep -E '^CONFIG_LOCALVERSION=' "$kcfg" | head -1 | cut -d'\"' -f2)"
+  fi
+  echo "${base_ver}${localver}"
+}
+
+modules_dir_for_full() {
+  local full="$1"
+  echo "/lib/modules/${full}"
+}
+
+full_kver="$(compute_full_kver)"
+container_modules_dir="$(modules_dir_for_full "$full_kver")"
+
+log "Container modules version: ${full_kver:-<unknown>}"
+if [[ -d "$container_modules_dir" ]]; then
+  before_count=$(find "$container_modules_dir" -type f -name '*.ko*' 2>/dev/null | wc -l | tr -d ' ')
+  log "Before build: ${container_modules_dir} exists with ${before_count} module file(s)"
+else
+  log "Before build: ${container_modules_dir} not present (fresh container scenario)"
+fi
+
 # Minimal set of stages to clear when zinit changes:
 # - zinit_setup: recopy zinit YAML and init scripts into initramfs
 # - validation: re-check initramfs contents
@@ -87,6 +195,7 @@ if [[ "$rebuild_kernel" -eq 1 ]]; then
 fi
 
 # Remove completion markers to force incremental rebuild of those stages
+log "Planned markers to clear: ${stages_to_clear[*]}"
 for s in "${stages_to_clear[@]}"; do
   marker="${STAGES_DIR}/${s}.done"
   if [[ -f "$marker" ]]; then
@@ -97,20 +206,39 @@ for s in "${stages_to_clear[@]}"; do
   fi
 done
 
+# Show stage status after marker removal (still host-safe)
+log "Stage status (after marker removal):"
+("${PROJECT_ROOT}/scripts/build.sh" --show-stages) || true
+
 # Build
 log "Starting incremental rebuild (zinit changes)"
-# If we plan to rebuild the kernel, force the pipeline to run from initramfs_create
+# IMPORTANT: Do NOT pass --rebuild-from or --force-rebuild; that would force ALL stages to run.
-# so the cpio archive is recreated before kernel_build (ignoring prior .done markers).
+# We rely exclusively on removed markers to minimally re-run only the necessary stages.
 build_from_args=()
-if [[ "$rebuild_kernel" -eq 1 ]]; then
-  build_from_args=(--rebuild-from=initramfs_create)
-  log "Rebuild-from: initramfs_create (guarantee cpio is recreated before kernel_build)"
-fi
 
-if [[ "$run_tests" -eq 1 ]]; then
+if in_container; then
-  log "Including boot tests"
+  # Run directly when already inside the dev/build container
+  if [[ "$run_tests" -eq 1 ]]; then
+    log "Including boot tests (in-container)"
     DEBUG=1 "${PROJECT_ROOT}/scripts/build.sh" "${build_from_args[@]}" "${extra_args[@]}"
-else
+  else
-  log "Skipping boot tests (use --run-tests to include)"
+    log "Skipping boot tests (in-container)"
     DEBUG=1 "${PROJECT_ROOT}/scripts/build.sh" --skip-tests "${build_from_args[@]}" "${extra_args[@]}"
+  fi
+else
+  # Not in container: delegate to dev-container manager which ensures container exists and is running
+  devctl="${PROJECT_ROOT}/scripts/dev-container.sh"
+  if [[ ! -x "$devctl" ]]; then
+    log "[ERROR] Dev container manager not found: ${devctl}"
+    log "[HINT] Run ./scripts/build.sh directly (it can start a transient container), or start the dev container via ./scripts/dev-container.sh start"
+    exit 1
+  fi
+
+  if [[ "$run_tests" -eq 1 ]]; then
+    log "Including boot tests via dev-container"
+    "$devctl" build "${build_from_args[@]}" "${extra_args[@]}"
+  else
+    log "Skipping boot tests via dev-container"
+    "$devctl" build --skip-tests "${build_from_args[@]}" "${extra_args[@]}"
+  fi
 fi