Fix USB install reliability: bash, LV resize, deps, idempotency

- autoinstall/user-data: move lvextend/growpart/pvresize BEFORE playbook
  so 130GB of drivers+PPKGs fits during first-boot copy. Use
  tr -d "[:space:]" to avoid breaking outer bash -c single-quote wrap.
- playbook: add executable: /bin/bash to Dell driver deploy (process
  substitution) and Blancco initramfs builder (brace expansion).
- playbook: make "Ensure Samba user for Blancco reports" idempotent via
  pdbedit check so re-runs don't abort the play.
- download-packages.sh: also download dist-upgrade package set. Explicit
  --simulate misses transitive version bumps (e.g. gnupg 17.4 needs
  matching gpgv 17.4) causing offline dpkg "dependency problems" when
  ISO baseline is older than noble-updates.

playbook/pxe_server_setup.yml

@@ -307,9 +307,19 @@
         mode: '0777'
 
     - name: "Deploy PPKG enrollment packages to enrollment share"
-      shell: cp -f {{ usb_mount }}/enrollment/*.ppkg /srv/samba/enrollment/ 2>/dev/null || true
-      args:
-        warn: false
+      shell: |
+        set +e
+        # Copy any whole PPKGs (small enough to fit on FAT32)
+        cp -f {{ usb_root }}/enrollment/*.ppkg /srv/samba/enrollment/ 2>/dev/null
+        # Reassemble any split files (foo.ppkg.part.00, .01, ... -> foo.ppkg)
+        for first in {{ usb_root }}/enrollment/*.part.00; do
+          [ -e "$first" ] || continue
+          base="${first%.part.00}"
+          name="$(basename "$base")"
+          echo "Reassembling $name from chunks..."
+          cat "${base}.part."* > "/srv/samba/enrollment/$name"
+        done
+        ls -lh /srv/samba/enrollment/*.ppkg 2>/dev/null
       ignore_errors: yes
 
     - name: "Deploy run-enrollment.ps1 to enrollment share"
@@ -320,16 +330,29 @@
       ignore_errors: yes
 
     - name: "Deploy Dell driver packs to shared Out-of-box Drivers"
-      shell: >
-        if [ -d "{{ usb_mount }}/drivers" ]; then
-          mkdir -p "/srv/samba/winpeapps/_shared/Out-of-box Drivers/Dell_11"
-          cp -r {{ usb_mount }}/drivers/* "/srv/samba/winpeapps/_shared/Out-of-box Drivers/Dell_11/"
-          echo "Deployed Dell drivers from USB"
-        else
-          echo "No drivers/ on USB - skipping"
-        fi
       args:
-        warn: false
+        executable: /bin/bash
+      shell: |
+        set +e
+        SRC="{{ usb_root }}/drivers"
+        DEST="/srv/samba/winpeapps/_shared/Out-of-box Drivers/Dell_11"
+        if [ ! -d "$SRC" ]; then
+          echo "No drivers/ on USB - skipping"
+          exit 0
+        fi
+        mkdir -p "$DEST"
+        # Copy everything except split chunks
+        rsync -a --exclude='*.part.*' "$SRC/" "$DEST/"
+        # Reassemble any split driver files
+        while IFS= read -r first; do
+          base="${first%.part.00}"
+          rel="${base#$SRC/}"
+          out="$DEST/$rel"
+          mkdir -p "$(dirname "$out")"
+          echo "Reassembling $rel from chunks..."
+          cat "${base}.part."* > "$out"
+        done < <(find "$SRC" -name '*.part.00')
+        echo "Deployed Dell drivers from USB"
       ignore_errors: yes
 
     - name: "Deploy shopfloor setup scripts to enrollment share"
@@ -372,6 +395,17 @@
         - models.txt
       ignore_errors: yes
 
+    - name: "Deploy BIOS update binaries from USB"
+      shell: >
+        if [ -d "{{ usb_root }}/bios" ]; then
+          cp -f {{ usb_root }}/bios/*.exe /srv/samba/enrollment/BIOS/ 2>/dev/null || true
+          count=$(find /srv/samba/enrollment/BIOS -name '*.exe' | wc -l)
+          echo "Deployed $count BIOS binaries"
+        else
+          echo "No bios/ on USB - skipping"
+        fi
+      ignore_errors: yes
+
     - name: "Create image upload staging directory"
       file:
         path: /home/pxe/image-upload
@@ -579,13 +613,24 @@
     # Boot Ubuntu kernel, download Blancco rootfs, overlay mount, switch_root.
 
     - name: "Build Blancco PXE initramfs"
+      args:
+        executable: /bin/bash
+        creates: "{{ web_root }}/blancco/kexec-initrd.img"
       shell: |
         set -e
         WORK=$(mktemp -d)
         mkdir -p "$WORK"/{bin,lib/modules,lib64,sbin,usr/share/udhcpc}
 
-        # Busybox (static)
-        cp /bin/busybox "$WORK/bin/" 2>/dev/null || apt-get install -y busybox-static >/dev/null && cp /bin/busybox "$WORK/bin/"
+        # Busybox (static) - bundled on USB at playbook/busybox-static
+        if [ -f /bin/busybox ]; then
+            cp /bin/busybox "$WORK/bin/"
+        elif [ -f "{{ usb_root }}/playbook/busybox-static" ]; then
+            cp "{{ usb_root }}/playbook/busybox-static" "$WORK/bin/busybox"
+            chmod +x "$WORK/bin/busybox"
+        else
+            echo "ERROR: No busybox available (not at /bin/busybox or on USB)"
+            exit 1
+        fi
         for cmd in sh awk cat chmod echo grep gunzip ifconfig ip ln losetup ls mkdir mknod mount reboot route sed sleep switch_root tar udhcpc umount wget cpio; do
             ln -sf busybox "$WORK/bin/$cmd"
         done
@@ -614,8 +659,7 @@
         find . | cpio -o -H newc 2>/dev/null | gzip > "{{ web_root }}/blancco/kexec-initrd.img"
         rm -rf "$WORK"
         echo "Built kexec-initrd.img: $(stat -c %s '{{ web_root }}/blancco/kexec-initrd.img') bytes"
-      args:
-        creates: "{{ web_root }}/blancco/kexec-initrd.img"
+      ignore_errors: yes
 
     - name: "Copy Ubuntu kernel for Blancco PXE boot"
       copy:
@@ -648,12 +692,11 @@
       args:
         creates: "{{ web_root }}/blancco/config-clean.xml"
 
-    - name: "Create Samba user for Blancco reports"
+    - name: "Ensure Samba user for Blancco reports exists (idempotent)"
       shell: |
-        id blancco 2>/dev/null || useradd -r -s /usr/sbin/nologin blancco
-        echo -e "blancco\nblancco" | smbpasswd -a -s blancco 2>/dev/null
-      args:
-        creates: /etc/samba/smbpasswd
+        id blancco >/dev/null 2>&1 || useradd -r -s /usr/sbin/nologin blancco
+        pdbedit -L 2>/dev/null | grep -q '^blancco:' || (echo -e "blancco\nblancco" | smbpasswd -a -s blancco)
+      changed_when: false
 
     - name: "Check for WinPE deployment content on USB"
       stat: