ZorOS 3.6 to USB-stick - Install howto

In this section some info about ZorOS CD live filesystem, scripts, language translations, tip and tricks

ZorOS 3.6 to USB-stick - Install howto

Postby zoros » Sat Sep 26, 2009 2:42 pm

Build an USB-stick filesystem:

Note: this filesystem uses syslinux to boot and may be installed only in first partition or as superfloppy ...
a true different solution is ZorOS Live USB-disk (this boot via initram and mount rw USB-device)

ZorOS CD is released only as ISO image, to extract USB image and devel script:
Code: Select all
# mkdir CDROM
# mount zoros-XX.iso CDROM -o loop
# cd CDROM
# ./rebuild.sh

Install to USB-stick:
Once extract USB image from ISO there are two methods to install it in USB-stick. In next example /dev/hdb is USB-stick device and default language is German (de).

Warning ! Be careful using dd command: if you send USB image to your HD device (example: /dev/hdb is your SATA disk and not USB-stick) you will destroy entire Hard Disk contents

1) using USB-stick as superfloppy
type simple:
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dd if=zoros-usb-3.6-de.img of=/dev/sdb bs=512

In this way we destroy USB-stick contents because this method rewrite sector 0 (MBR) and device is mapped as large floppy (<50Mb floppy). However is possible to make a backup of fist 50M of USB-stick and restore image later:

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dd if=/dev/sdb of=first-50M-usb.img bs=512 count=100000

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dd if=first-50M-usb.img of=/dev/sdb bs=512

2) using USB-stick as hard disk
This is preferred method, so "fdisk -l" not list errors about USB-stick partitions (MBR report inconsistent partitions table because MBR is boot record of FAT filesystem and not a true MBR)

- step 1: with fdisk /dev/sdb make 2 partitions

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Device        Boot     Start     End      Blocks    Id    System
/dev/sdb1      *          1       101      49257+   b    W95 FAT32
/dev/sdb2               102      1023    449936     b    W95 FAT32

(in example a 500M USB-stick)

- step 2: copy ZorOS USB image
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dd if=zoros-usb-3.6-de.img of=/dev/sdb1 bs=512

- step 2: make fileystem in /dev/sdb2
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mkdosfs -F32 /dev/hdb2

- step 3: copy syslinux boot code in USB-stick MBR
syslinux boot code is in ISO cdrom (./CDROM/isolinux/mbr.bin or ./rebuild-zoros-cd/isolinux/mbr.bin)
Code: Select all
dd if=./rebuild-zoros-cd/isolinux/mbr.bin of=/dev/sdb

Note: mbr.bin is 404 byte length and not rewrite table partitions
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