1. Deploy gea-standard / gea-engineer FlatUnattendW10.xml
The playbook only copied the shopfloor variant before; standard and
engineer's unattend was hand-staged on the running servers. New task
loops the repo's playbook/FlatUnattendW10.xml into Deploy/ for each
entry in standard_types (new var covering gea-standard, gea-engineer,
ge-standard, ge-engineer). force: yes because repo drift vs deployed
copy is what produced the Win10/Win11 search-cleanup regression
earlier this session (d49f516).
2. Deploy Oracle Client 11.2 preinstall payload
preinstall.json now leads with Oracle 11.2 (commit 3a29784). The CMD
wrapper is tracked in the repo at playbook/preinstall/oracle/; the
686 MB Oracle_OracleDatabase_11r2_V03.zip is too large to commit and
rides on USB under oracle/ alongside BIOS exes. Three tasks:
mkdir staging dir, copy CMD from usb_mount, copy zip from usb_root
with a soft-fail + warning if absent.
3. No change needed for sync-preinstall.sh — Oracle 10.2.0.3 flat
installer was already dropped in 9235d19.
YAML lints clean. Fresh server built from this commit will bring up
Blancco-agnostic imaging paths correctly; Blancco-specific gaps
(grubx64.efi native-vs-slim, narrow kexec-initrd driver tree,
narrow blancco-init.sh) are still deferred per earlier "option B"
decision and remain server-side-pinned only.
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
User reports Blancco was working before our mirror/session activity
today - then my attempted fixes (grubx64.efi rebuild, kexec-initrd
driver sweep, verbose blancco-init.sh) made it worse:
- First attempt (narrow igc driver add) did not help because the
switch-root path was not the one actually loaded by grubx64.efi's
embedded config.
- Second attempt (swapped grub embedded config to Ubuntu-kernel path)
got further, but then kexec-initrd modules failed on insmod.
- Third attempt (full ethernet tree sweep) pulled in broken ancient
drivers (winbond-840, w5100-spi, xirc2ps_cs) that failed with
unknown-symbol errors and prevented good drivers from loading.
Full revert: .gitignore, blancco-init.sh, pxe_server_setup.yml back to
the pre-session commit 6dcf832 state. Removes boot-tools/blancco/grub-
blancco.cfg from git (it was only added this session).
Runtime on both PXE servers was also restored: grubx64.efi and
kexec-initrd.img reverted from the .bak files taken before each
modification this session.
Whatever was there before today is now restored byte-for-byte on both
servers. If there is still a Blancco boot issue on specific modern
hardware that the user needs to fix, we will diagnose that narrowly
against the actual failure mode on that specific machine, not by
making sweeping preemptive changes.
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
Previous approach listed ~6 specific drivers (e1000e, igb, tg3, bnx2,
bnxt_en, b44) and silenced insmod errors (2>/dev/null). On modern Dell
fleet (Latitude 5330/5440, Pro-series, newer OptiPlex) this missed
igc (Intel I225/I226) entirely, and for the drivers we did include,
dependency modules they need at insmod time (libeth, libie, dca,
i2c-algo-bit, macsec, mii, libphy, ptp, ...) were never bundled.
insmod does not resolve dependencies, so NIC drivers that need
helpers failed to load silently.
playbook/pxe_server_setup.yml (kexec-initrd build):
- Sweep the whole drivers/net/ethernet tree (~170 drivers, all
vendors, ~15 MB total). Drivers for hardware not present skip
without binding.
- Add common helper dirs: drivers/net/{phy,mdio}, drivers/i2c/algos,
drivers/dca, drivers/ptp, net/macsec, drivers/ssb.
- overlay.ko kept.
playbook/blancco-init.sh:
- Load helpers BEFORE main NIC drivers (libeth/libie, dca,
i2c-algo-bit, macsec, mii, ssb, libphy, mdio*, phy*, ptp*),
then iterate remaining modules.
- Remove 2>/dev/null on insmod so actual failures surface on the
boot console.
- Print kernel version + /sys/class/net before/after driver load,
plus dmesg grep for NIC driver activity.
- On "no interface found" failure, dump dmesg tail and drop to a
busybox shell for manual debug rather than just hanging.
Separate from this commit but related: kexec-initrd.img on both PXE
servers (.1 and .2) was rebuilt inline with these changes. Pre-rebuild
binary kept as kexec-initrd.img.bak-<timestamp>.
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
Three changes that go together so a re-image never hits "System error 53":
1. dnsmasq dhcp-script hook (playbook/pxe-server-helpers/pxe-dhcp-hook.sh)
Fires on every add/del lease event. Runs conntrack -D and ss -K for the
client IP so any stale ESTABLISHED SMB session from a previous boot is
cleared before the client reconnects. Runs as root (dnsmasq default).
Wired into /etc/dnsmasq.conf via dhcp-script= directive in the playbook.
2. One-source PPKG (playbook/startnet.cmd + startnet-template.cmd)
The 5 per-Office PPKG copies were bit-for-bit identical; only the
filename differs because BPRT parses Office and Region out of the name.
Store one source file (e.g. GCCH_Prod_SFLD_v4.11.ppkg) and construct
the BPRT-tagged target filename at menu-selection time from variables:
SOURCE_PPKG / PPKG_VER / PPKG_EXP / REGION / OFFICE
copy /Y "Y:\ppkgs\%SOURCE_PPKG%" "W:\Enrollment\%PPKG%"
Bumped PPKG_VER v4.10 -> v4.11 and PPKG_EXP 20260430 -> 20270430.
Saves ~30G on disk per version.
3. run-enrollment.ps1 already committed in 5a9c3db uses provtool.exe
directly (no PowerShell cmdlet 180s timeout). Included here because it
is part of the same end-to-end PPKG path.
Workstation reorganization:
- All build/deploy/helper scripts moved into scripts/ (paths updated to use
REPO_ROOT instead of SCRIPT_DIR so they resolve sibling dirs from the new
depth)
- New config/ directory placeholder for site-specific overrides
- Removed stale: mok-keys/, test-vm.sh, test-lab.sh, setup-guide-original.txt,
unattend/ (duplicate of moved playbook/FlatUnattendW10.xml)
- README.md and SETUP.md structure listings updated, dead "Testing with KVM"
section removed
- .claude/ gitignored
Enrollment share internal taxonomy (forward-looking; existing servers
unaffected since they keep their current boot.wim with flat paths):
- Single SMB share kept (WinPE only mounts one Y: drive), but content now
organised into ppkgs/, scripts/, config/, shopfloor-setup/, pre-install/{bios,
installers}, installers-post/cmm/, blancco/, logs/
- README.md deployed to share root explaining each subdir
- New playbook tasks deploy site-config.json + wait-for-internet.ps1 +
migrate-to-wifi.ps1 explicitly (were ad-hoc on legacy servers)
- BIOS subdir moved into pre-install/bios/, preinstall/ renamed to pre-install/
- startnet.cmd + startnet-template.cmd updated with new Y:\subdir\ paths
- Bumped GCCH PPKG references v4.9 -> v4.10
Blancco USB-build fixes (so next fresh USB install boots Blancco end-to-end
without the manual fixup we did against GOLD):
- grub-blancco.cfg: kernel/initrd switched HTTP -> TFTP (GRUB's HTTP module
times out on multi-MB files); added modprobe.blacklist=iwlwifi,iwlmvm,btusb
(WiFi drivers hang udev on Intel business PCs)
- grubx64.efi rebuilt from updated cfg
- Playbook task added to create /srv/tftp/blancco/ symlinks pointing at the
HTTP-served binaries
run-enrollment.ps1: OOBEComplete is now set AFTER PPKG install (Win11 22H2+
hangs indefinitely if OOBEComplete is set before the bulk-enrollment PPKG runs).
Also includes deploy-bios.sh / pull-bios.sh / busybox-static / models.txt
that were sitting untracked at the repo root.
- 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.
- PreInstall runner reads pc-subtype.txt and matches PCTypes against
both base type (Standard) and composite key (Standard-Machine).
- UDC scoped to Standard-Machine only. eDNC and MachineNumberACLs
skip on Standard-Timeclock sub-type.
- Lab added to OpenText PCTypes.
- build-usb.sh copies enrollment/ (PPKGs) and drivers-staging/ (Dell
driver packs) onto USB for self-contained deployment.
- Playbook deploys PPKGs and drivers from USB to PXE server shares.
- Gitignore enrollment/, drivers-staging/, *.ppkg (large binaries).
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
- Monitor-IntuneProgress: Display PCs skip DSC phases entirely (no SAS
token, no DSCInstall.log), complete after Phase 1 identity. Renderer
hides Phase 2-5 for Display type.
- Playbook: deploy PPKG files and run-enrollment.ps1 from USB to
enrollment share. Bump dnsmasq restart cron from 15s to 30s.
- build-usb.sh: copy enrollment/ directory (PPKGs) onto USB if present.
- user-data: add dpkg --configure -a after offline .deb install to fix
packages left in unconfigured state (cron, systemd-timesyncd).
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
WinPE clients re-imaging the same machine hit "System error 53 -
network path not found" on the second attempt. systemctl restart smbd
did not help; only a full server power cycle cleared the state.
Root cause is kernel nf_conntrack: the default TCP ESTABLISHED timeout
is 5 days (432000s), so a session from the first WinPE run whose
client rebooted abnormally leaves an ASSURED ESTABLISHED entry that
ufw's state-tracking rules then mis-classify the new SYN against.
Fix applied in three layers:
- /etc/sysctl.d/99-pxe-conntrack.conf drops TCP ESTABLISHED timeout
to 1 hour and shortens the half-closed states to 30s each.
- smb.conf gains socket options TCP_NODELAY SO_KEEPALIVE IPTOS_LOWDELAY
plus keepalive = 30 and deadtime = 5. Active sessions refresh the
conntrack timer every 30s via keepalives so they never age out;
dead ones expire in an hour.
- /usr/local/sbin/smb-diag.sh snapshots kernel + Samba state for
remote diagnosis; /usr/local/sbin/smb-soft-reset.sh walks a
progressive recovery (nmbd/smbd restart, conntrack flush, arp
flush, ss -K) as an alternative to power-cycling.
conntrack package added to download-packages.sh and playbook verify
list so the offline .deb bundle ships with it.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Adds a local-install pipeline so Standard shopfloor PCs get Oracle, the
VC++ redists (2008-2022), and UDC installed during PXE imaging via Samba
instead of pulling ~215 MB per device from Azure blob over the corporate
WAN. Intune DSC then verifies (already-installed apps are skipped) and
the only Azure traffic on the happy path is ~11 KB of CustomScripts
wrapper polling.
New files:
- playbook/preinstall/preinstall.json — curated app list with PCTypes
filter and per-app detection rules. Install order puts VC++ 2008
LAST so its (formerly) reboot-triggering bootstrapper doesn't kill
the runner mid-loop. (2008 itself now uses extracted vc_red.msi with
REBOOT=ReallySuppress; the reorder is defense in depth.)
- playbook/shopfloor-setup/Shopfloor/00-PreInstall-MachineApps.ps1 —
the runner. Numbered 00- so it runs first in the baseline sequence.
Reads preinstall.json, filters by PCTYPE, polls for completion via
detection check (handles UDC's hung WPF process by killing it once
detection passes), uses synchronous WriteThrough logging that
survives hard reboots, preserves log history across runs.
- playbook/shopfloor-setup/Standard/Set-MachineNumber.{ps1,bat} — desktop
helper for SupportUser. Reads current UDC + eDNC machine numbers,
prompts via VB InputBox, validates digits-only, kills running UDC,
edits both C:\ProgramData\UDC\udc_settings.json and HKLM\…\GE Aircraft
Engines\DNC\General\MachineNo, relaunches UDC. Lets a tech assign a
real machine number to a mass-produced PC without admin/LAPS.
- playbook/sync-preinstall.sh — workstation helper to push installer
binaries from /home/camp/pxe-images/main/ to the live PXE Samba.
Changes:
- playbook/startnet.cmd + startnet-template.cmd — add xcopy to stage
preinstall bundle from Y:\preinstall\ to W:\PreInstall\ during the
WinPE imaging phase, gated on PCTYPE being set.
- playbook/pxe_server_setup.yml — create /srv/samba/enrollment/preinstall
+ installers/ directories and deploy preinstall.json there.
- playbook/shopfloor-setup/Run-ShopfloorSetup.ps1 — bump AutoLogonCount
to 99 at start (defense against any installer triggering an immediate
reboot mid-dispatcher; final line still resets to 2 on successful
completion). Copy Set-MachineNumber.{ps1,bat} to SupportUser desktop
on Standard PCs.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Ansible cron module writes to root's crontab which requires cron
daemon running. Drop file in /etc/cron.d/ instead for reliability.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Not needed since iPXE chains to grubx64.efi for Blancco boot.
Simplifies DHCP config and avoids interfering with other UEFI clients.
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
Webapp now creates Deploy/Control/Media.tag after every image import.
Cron updated to create (not just touch) Media.tag for any image
directory that has Deploy/Control/.
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
PESetup.exe checks Media.tag last modified date and rejects it after
30 days. Cron job touches all Media.tag files daily at midnight.
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
- Add startnet.cmd: FlatSetupLoader.exe + Boot.tag/Media.tag eliminates
physical USB requirement for WinPE PXE deployment
- Add Upload-Image.ps1: PowerShell script to robocopy MCL cached images
to PXE server via SMB (Deploy, Tools, Sources)
- Add gea-shopfloor-mce image type across playbook, webapp, startnet
- Change webapp import to move (not copy) for upload sources to save disk
- Add Samba symlink following config for shared image directories
- Add Media.tag creation task in playbook for drive detection
- Update prepare-boot-tools.sh with Blancco config/initramfs patching
- Add grub-efi-amd64-bin to download-packages.sh
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
- Playbook: detect interface already configured with 10.9.100.1 before
falling back to non-default-gateway heuristic (fixes dnsmasq binding
to wrong NIC when multiple interfaces exist)
- test-vm.sh: auto-attach br-pxe bridge NIC if available on host
- Webapp: add network upload import via SMB share with shared driver
deduplication and symlinks
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
- Move Flask to localhost:9010, Apache serves port 9009 with static file
handling and reverse proxy to fix intermittent asset loading on remote clients
- Add "PXE Manager" branding beneath logo in sidebar
- Increase code editor size (startnet.cmd and unattend XML) to 70vh
- Add test-lab.sh for full lab VM testing
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
- Add build-proxmox-iso.sh: remaster Ubuntu ISO with autoinstall config,
offline packages, playbook, webapp, and boot files for zero-touch
Proxmox VM deployment
- Add boot-files/ directory for WinPE boot files (wimboot, boot.wim,
BCD, ipxe.efi, etc.) sourced from WestJeff playbook
- Update build-usb.sh and test-vm.sh to bundle boot-files automatically
- Add usb_root variable to playbook, fix all file copy paths to use it
- Unify Apache VirtualHost config (merge default site + webapp proxy)
- Add CSRF token protection to all webapp POST forms and API endpoints
- Update README with Proxmox deployment instructions
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
- Fix pip/distutils incompatibility: install Python wheels directly via
zipfile extraction instead of broken pip3 from Ubuntu 22.04 .debs
(pip3 crashes on Python 3.12 with ModuleNotFoundError: distutils)
- Fix UFW port types: quote loop items so string comparison works
correctly, giving ports 67/69 UDP rules instead of TCP
- Fix autoinstall crash: set refresh-installer to no (can't reach
internet on air-gapped network, was crashing subiquity)
- Remove python3-pip and python3-venv from download-packages.sh
(no longer needed with direct wheel extraction)
- Add ignore_errors to WinPE/iPXE copy tasks (files only present
on real USB media, not test VM)
- Use system python3 instead of venv for webapp service
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
- Add comprehensive README.md with full project documentation
- Update SETUP.md to reflect current state (7 image types, webapp, boot tools, Samba shares)
- Enable SSH in autoinstall user-data for remote access
- Fix ansible_default_ipv4.interface error when no default gateway exists
- Fix Windows CRLF line endings on all shell scripts and YAML files
- Fix test-vm.sh: use --install kernel extraction instead of --location, don't delete source ISO on --destroy
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
- Webapp now listens on port 9009 (UFW rule added)
- Apache reverse proxy updated to proxy to 9009
- test-vm.sh creates a KVM test environment with:
- CIDATA ISO built from project files
- Isolated libvirt network (10.9.100.0/24)
- Ubuntu 24.04 VM with autoinstall
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
- Samba share at \\server\blancco-reports for automatic report collection
- Webapp reports page with list, download, and delete
- Compliance warning on delete confirmation
- Sidebar link under Tools section
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
- Added wimtools to offline packages and playbook verification
- Webapp startnet.cmd editor: extract, view, edit, save back to boot.wim
- Uses wimextract/wimupdate for in-place WIM modification
- Dark-themed code editor with tab support and common command reference
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
- iPXE boot menu with WinPE, Clonezilla, Blancco Drive Eraser, Memtest86+
- prepare-boot-tools.sh to download/extract boot tool binaries
- Clonezilla backup management in webapp (upload, download, delete)
- Clonezilla Samba share for network backup/restore
- GE Aerospace logo and favicon in webapp
- Updated playbook with boot tool directories and webapp env vars
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
- webapp/: Flask web management app with:
- Dashboard showing image types and service status
- USB import page for WinPE deployment content
- Unattend.xml visual editor (driver paths, specialize commands,
OOBE settings, first logon commands, raw XML view)
- API endpoints for services and image management
- SETUP.md: Complete setup documentation for streamlined process
- build-usb.sh: Now copies webapp and optional WinPE images to USB
- playbook: Added webapp deployment (systemd service, Apache reverse
proxy), offline package verification, WinPE auto-import from USB
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
Reorganized from OneDrive export into a clean project structure:
- autoinstall/: cloud-init user-data and meta-data for Ubuntu 24.04 autoinstall
- playbook/: Ansible playbook for PXE server config (dnsmasq, Apache, Samba, iPXE)
- unattend/: Windows unattend.xml sample for image deployment
- build-usb.sh: builds a bootable USB with Ubuntu installer + CIDATA partition
- download-packages.sh: downloads all offline .deb dependencies via Docker
Key improvements over original:
- Fully air-gapped: all packages bundled offline, no WiFi needed
- Hardware-agnostic network config (wildcard NIC matching)
- Removed plaintext WiFi credentials
- Single USB build process (was 15+ manual steps)
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
