04db6d6605
Everything West Jefferson specific moved out to a separate repo (pxe-site-wj): NTLARS/UDC/heat-treat backups keyed by WJ machine numbers, CMM and Wax/Trace bay lists, WJ OpenText profiles, site-config.json, the WJ preinstall list, and the WJ shopfloor PC types (Collections, NoCollections, Common, Keyence, CMM, Genspect, HeatTreat, Wax/Trace, Display, PartMarker) with GE-Enforce, machine numbers and the desktop layout. The part-marker bench tools moved to their own repo. Dead scripts removed: build-proxmox-iso, deploy-bios, sync_hardware_models, mirror-from-gold, pull-bios, startnet-template.cmd. Shopfloor is one generic type, gea-shopfloor-standard, with today's timing: - PPKG at first logon (unattend Order 10, unchanged). - Install-AppList.ps1 runs C:\PreInstall\preinstall.json during setup. - A new SYSTEM task, GE Shopfloor Post-PPKG, runs postppkg.json once after the post-PPKG reboot. It also clears AutoLogonCount after the ShopFloor handover (the Users-level monitor can be denied that HKLM write) and removes the Intune Sync task when done. - Both lists ship empty. A site adds entries and installers. - WinPE choice 3 goes straight to the PPKG menu. Staging, fetch and heal carry only the generic payload. The webapp's shopfloor sub-menu editor is gone, and the imaging tiles name the new stages. - The playbook deploys the empty lists only if missing. It now deploys the PowerShell 7 MSI the shopfloor unattend installs, which it never did before. Blancco site settings move into the webapp (Updates > Blancco releases): business location, licensing Wi-Fi SSID and password. They are rendered into the served preferences.xml and applied to every staged release, and are seeded from site-vars (site_name, blancco_wifi_ssid, blancco_wifi_password) only while none exist. The repo XML carries no site values; the plaintext Wi-Fi password is gone from it. New site_name and site_timezone settings: report and evidence-pack site name, server clock and webapp time zone. No more West Jefferson defaults in webapp/config.py or the dashboard title. Sync-BPRT.ps1 gets the server address filled in at download instead of WJ's GE address. USB on Windows: - scripts/Build-PxeUsb.ps1 runs the same checks as build-usb.sh. It writes one FAT32 CIDATA partition (ISO files plus patched grub.cfg plus payload) with diskpart and reads every file back by SHA-256. - Tested with Windows PowerShell 5.1 in the win11 VM, and the layout installs and first-boots in the pxetest VM. - scripts/stage-usb-share.sh stages the build folder on a share. - site-content/ is optional for both builders. KB docs/kb/How_To_Deploy_PXE_Server_New_Site.html: new-site deployment, Windows only, with a site-vars.yml guide. Checks: webapp tests pass (5 suites); the unattend lint and playbook syntax checks pass; every .ps1 parses; there are no WJ hosts, IPs, names or PC types in playbook/, webapp/, scripts/ or autoinstall/.
16 KiB
PXE Server Setup Guide
Automated build process for deploying an Ubuntu-based PXE boot server that hosts GE Aerospace Windows PE images. The entire setup is air-gapped — no internet required on the target machine.
Architecture
Client PXE boot
-> Broadcom signed iPXE (Secure Boot)
-> iPXE boot menu (HTTP, port 4433)
├── Windows PE -> wimboot -> boot.wim -> startnet.cmd -> Samba -> Image deployment
├── Clonezilla -> vmlinuz/initrd -> Disk cloning/imaging
├── Blancco -> Native kernel + initramfs -> NIST 800-88 drive erasure (auto-reports)
(memory test: Dell F12 > Diagnostics)
Services on the PXE Server
| Service | Port | Purpose |
|---|---|---|
| dnsmasq | 67/udp | DHCP (172.16.9.10-100) |
| dnsmasq | 69/udp | TFTP (serves ipxe.efi) |
| Apache | 80/tcp | HTTP (wimboot, WinPE boot files, proxy) |
| Apache | 4433/tcp | iPXE boot script (GetPxeScript.aspx) |
| Samba | 445/tcp | Deployment content + backup + reports |
| Flask Webapp | 9009/tcp | Web management interface |
Prerequisites
Hardware
- Server or PC with >= 8 GB RAM, >= 250 GB disk, one wired NIC
- USB thumb drive >= 8 GB (32+ GB if bundling WinPE images)
Software (on your workstation)
- Ubuntu Server 24.04 ISO — https://ubuntu.com/download/server
- Linux workstation (Ubuntu/Mint) for running download and build scripts
- GE Aerospace Media Creator LITE (for caching WinPE images)
GE Access Packages
- EPM Rufus Exception Request
- EPM DT Functions
- DLP - Encrypted Removable (USB) Long Term Access
Setup Process
Step 1: Download Offline Packages (one-time, requires internet)
./scripts/download-packages.sh --iso /path/to/ubuntu-24.04.x-live-server-amd64.iso
./scripts/check-updates.py # expect: PASSED, 0 security updates
./scripts/fetch-ipxe.sh
fetch-ipxe.sh downloads the Secure Boot iPXE chain into boot-files/, pinned by sha256: the iPXE release
tarball (its snponly build becomes ipxe.efi) and iPXE's dual-signed shim (Microsoft UEFI CA 2011 + 2023),
which every UEFI client boots as ipxe-shim.efi. Keep the old Broadcom-signed boot-files/ipxe.efi too: the
playbook installs it as ipxe-bcm.efi, the rollback boot file.
download-packages.sh needs docker (no sudo) and the SAME server ISO that
build-usb.sh will use. The install is offline (autoinstall uses a dead
mirror on purpose), so the server's base is exactly that ISO's; the script
unpacks the ISO's install image into a docker image and resolves there:
every update of an installed package, the explicit package list
(ansible, dnsmasq, apache2, samba, wimtools, zip, the HWE kernel, ...) and
the newest version of what the installer adds from the ISO's pool (kernel,
grub, openssh-server). offline-packages/ becomes an apt repository
(debs + Packages + explicit.list), checked offline in a fresh container
of the base before the script finishes. On the server, autoinstall's
late-commands run scripts/offline-apt-install.sh on it: one apt
transaction from the local repo only, any error fails the install (log:
/var/log/offline-apt-install.log). The webapp's pinned, hashed wheels go
to pip-wheels/. About 500 debs (~1.6 GB) + 8 wheels.
Packages included:
- Server: dnsmasq, apache2, samba, ufw, cron
- Automation: ansible
- Tools: wimtools, unzip, p7zip-full
- Python: python3-pip, python3-venv
- Network: network-manager, wpasupplicant, wireless-tools, linux-firmware
Step 2: Prepare Boot Tools (optional)
./scripts/prepare-boot-tools.sh /path/to/blancco.iso
Extracts boot files for Blancco and Clonezilla (64-bit with Debian's signed shim, so it boots with Secure Boot on, plus the last 32-bit release for XP-era PCs) into the boot-tools/ directory. Automatically patches Blancco's config.img to auto-save erasure reports to the PXE server's Samba share.
Step 2b: Capture site content from a running server
./scripts/capture-site-content.sh # dry run: lists what would change
./scripts/capture-site-content.sh --apply # pull it
Pulls what neither the repo nor the MCL image import brings, from a working PXE server (default 172.16.9.1, SSH key login as pxe): _shared/Applications/extra (Office, Adobe, OpenText, Java, fonts, Wi-Fi, Zscaler), the GE CA certificates and the Engineering Layer payload in each image's Deploy/Applications, and the links images keep there, into site-content/. It also refreshes bios-staging/ (BIOS files and models.txt), boot-files/boot.wim and the Blancco files in boot-tools/blancco/ from the server. It writes site-content/SHA256SUMS, which the playbook checks before restoring anything, and refuses content a FAT32 USB cannot hold. Without it a new server cannot build Standard or Engineer (build-usb.sh refuses unless you pass --skip-site-content).
The first MCL image import on the new server then seeds _shared/Applications/BPRT, adding our overlay scripts from the repo.
Step 3: Build the USB
# Basic: server only (import WinPE images later). site-vars.yml holds the
# two NIC MACs (copy playbook/site-vars.example.yml); --site-vars or
# --no-site-vars is required.
sudo ./scripts/build-usb.sh --site-vars site-vars.yml /dev/sdX /path/to/ubuntu-24.04-live-server-amd64.iso
# With WinPE images bundled (single USB, larger drive needed; no file may
# be 4 GiB or more, FAT32)
sudo ./scripts/build-usb.sh --site-vars site-vars.yml /dev/sdX /path/to/ubuntu-24.04.iso /path/to/winpe-images
# Same layout into a disk-image file, no root (dd it to a stick later, or
# boot it in a VM: see tests/vm/README.md; on Proxmox: qm importdisk).
# SIZE is e.g. 16G or "auto".
./scripts/build-usb.sh --site-vars site-vars.yml --image pxe-usb.img auto /path/to/ubuntu-24.04.iso
Options: --payload-root DIR takes offline-packages/, pip-wheels/,
boot-files/, boot-tools/, enrollment/, bios-staging/ and drivers-staging/
from another checkout; --skip-enrollment, --skip-bios,
--skip-drivers, --skip-boot-tools leave those out; --yes skips the
prompt. The build refuses payloads that do not match their pins: the iPXE
files against the playbook's ipxe_*_sha256, each wheel against its own
package's hashes in webapp/requirements.txt (no PyPI fallback), and the
ISO against the volume id offline-packages/iso-volid was resolved for. The ISO volume label and El Torito load sizes are read from the
ISO, so any 24.04.x point release works.
This creates a bootable USB with:
- Partition 1: Ubuntu Server installer
- Partition 2: CIDATA (autoinstall config, offline .debs, pip wheels, Ansible playbook, webapp, boot tools)
Building the USB on a Windows PC
scripts/Build-PxeUsb.ps1 builds the same stick on Windows, with the same
checks, no Linux tools needed. It writes ONE FAT32 partition labelled
CIDATA holding the Ubuntu ISO's files (boot menu patched for autoinstall)
and the payload; it boots in UEFI mode only (Secure Boot works) and is at
most 32 GB (the FAT32 size Windows formats). Every file is read back and
compared by SHA-256.
On the build PC, put the repo and payload on the share:
./scripts/stage-usb-share.sh # -> ~/pxe-images/pxe-usb (hard links)
On the Windows PC, in an elevated PowerShell (Z: = the pxe-images share):
Z:\pxe-usb\scripts\Build-PxeUsb.ps1 # lists USB disks
Z:\pxe-usb\scripts\Build-PxeUsb.ps1 -DiskNumber 3 -NoSiteVars # or -SiteVars FILE
It refuses a disk that is not on the USB bus or is the boot/system disk, and asks you to type the disk number before erasing it.
Step 4: Boot the Target Machine
- Insert the USB into the target machine
- Press F12 (or vendor boot key) and select the USB
- Ubuntu auto-installs — no interaction needed
- After reboot, the first-boot script runs the Ansible playbook (the .debs were installed by the installer); it pins the two NICs by MAC
- PXE services (dnsmasq, Apache, Samba) are configured automatically
- Flask webapp starts on port 9009
- If the playbook fails,
/var/lib/pxe-firstboot.failedand a banner on the console and at SSH login point at/var/log/first-boot.log; first boot retries at the next reboot (5 attempts)
Step 5: Connect to Isolated Network
During the install plug in ONLY the imaging switch (GE unplugged). With
pxe_nic_mac empty in site-vars, the first boot picks the one wired port
with a link, checks it is isolated (no GE switch, no 802.1X, no other DHCP
server) and pins it. Then plug the GE cable into any other port: it becomes
a DHCP client for SSH and the webapp, and dnsmasq never serves it. If the
first boot cannot tell which port is the imaging one, the console says so:
log in and run sudo pxe-pick-nic, pull the imaging cable and plug it back
in. Sites that prefer to pin both ports by MAC set pxe_nic_mac and
corp_nic_mac instead; both cables can then be in from the start.
Step 6: Import WinPE Content (if not bundled in Step 3)
Option A: Use the web interface at http://172.16.9.1:9009 to import from USB.
Option B: Manual copy:
sudo mkdir -p /mnt/usb2
sudo mount /dev/sdb2 /mnt/usb2
sudo cp -r /mnt/usb2/. /srv/samba/winpeapps/gea-standard
sudo umount /mnt/usb2
Web Management Interface
Access at http://172.16.9.1:9009 from any machine on the isolated network.
| Page | URL Path | Purpose |
|---|---|---|
| Dashboard | / | Service status, disk usage, DHCP clients |
| Image Import | /import | Import WinPE images from USB drives |
| Unattend Editor | /unattend | Edit Windows unattend.xml per image type |
| startnet.cmd | /startnet | Edit startnet.cmd inside boot.wim (wimtools) |
| Clonezilla Backups | /backups | Upload/download/manage disk backup images |
| Blancco Reports | /reports | View/download drive erasure reports |
| Image Config | /images/*/config | Per-image driver, OS, and hardware config |
| Enrollment | /enrollment | GCCH bulk enrollment package management |
| Audit Log | /audit | Activity history for all write operations |
Verification
- Connect a test workstation to the isolated switch
- Set Network Boot (PXE) as first boot in BIOS/UEFI
- Boot — the client should pull an IP from 10.9.100.x
- iPXE loads, fetches the boot script from port 4433
- Select an option from the boot menu:
- Windows PE: Boots via wimboot + boot.wim, maps Samba shares, begins deployment
- Clonezilla: Boots Clonezilla Live for disk imaging
- Blancco: Boots Drive Eraser, auto-saves reports to server
- Memory test: not on the menu; Dell PCs have one built in (F12 at power-on, Diagnostics)
Testing with KVM
# Download Ubuntu ISO
wget -O ~/Downloads/ubuntu-24.04.3-live-server-amd64.iso \
https://releases.ubuntu.com/noble/ubuntu-24.04.3-live-server-amd64.iso
# Launch test VM
sudo ./test-vm.sh ~/Downloads/ubuntu-24.04.3-live-server-amd64.iso
# Watch progress (Ctrl+] to detach)
sudo virsh console pxe-test
# After install: ssh pxe@172.16.9.1 / http://172.16.9.1:9009
# Clean up
sudo ./test-vm.sh --destroy
Project Structure
pxe-server/
├── autoinstall/
│ ├── user-data # Cloud-init autoinstall + first-boot script
│ └── meta-data # Cloud-init metadata (required, empty)
├── playbook/
│ ├── pxe_server_setup.yml # Ansible: dnsmasq, Apache, Samba, iPXE, UFW, webapp
│ ├── inventory.ini # Ansible inventory
│ ├── startnet.cmd # WinPE startup script (injected into boot.wim)
│ ├── blancco-init.sh # Custom initramfs for Blancco PXE boot
│ ├── blancco-preferences.xml # Blancco auto-report preferences
│ ├── check-bios.cmd # Pre-imaging BIOS update checker
│ ├── FlatUnattendW10-shopfloor.xml # Shopfloor unattend.xml
│ └── shopfloor-setup/ # PC type setup scripts (Standard, CMM, Display, etc.)
├── webapp/
│ ├── app.py # Flask application (~1600 lines)
│ ├── requirements.txt # Python deps (flask, lxml)
│ ├── static/ # CSS, JS, fonts, logo (all bundled offline)
│ └── templates/ # Jinja2 HTML templates (10 pages)
├── docs/
│ └── shopfloor-display-imaging-guide.md # End-user imaging guide
├── boot-tools/ # Extracted boot files (gitignored, built by prepare-boot-tools.sh)
│ ├── blancco/ # Blancco Drive Eraser
│ └── clonezilla/ # Clonezilla Live
├── boot-files/ # WinPE boot files (boot.wim, wimboot, ipxe.efi, BCD)
├── offline-packages/ # .deb files (gitignored, built by download-packages.sh)
├── pip-wheels/ # Python wheels (gitignored, built by download-packages.sh)
├── enrollment/ # PPKGs and run-enrollment.ps1 (gitignored)
├── bios-staging/ # Dell BIOS update binaries (gitignored)
├── scripts/ # Build, deploy, and helper scripts
│ ├── build-usb.sh # Builds the 2-partition installer USB
│ ├── Build-PxeUsb.ps1 # Windows: builds the installer USB (one FAT32 partition)
│ ├── stage-usb-share.sh # Puts repo + payload on the pxe-images share for it
│ ├── prepare-boot-tools.sh # Extracts/patches boot tools from ISOs
│ ├── download-packages.sh # Downloads all offline packages
│ ├── download-drivers.py # Downloads Dell drivers from dell.com
│ ├── capture-site-content.sh # Pulls site content + fresh payload from a live server
│ ├── Upload-Image.ps1 # Windows: upload MCL cache to PXE via SMB
│ └── Download-Drivers.ps1 # Windows: download hardware drivers from GE CDN
├── config/ # Site-specific configuration overrides
├── README.md # Project overview
└── SETUP.md # Detailed setup guide (this file)
Image Types
| Image Type | Domain | Description |
|---|---|---|
| gea-standard | geaerospace.com | Standard desktop |
| gea-engineer | geaerospace.com | Engineering desktop |
| gea-shopfloor | geaerospace.com | Shop floor kiosk |
| ge-standard | ge.com | Standard desktop |
| ge-engineer | ge.com | Engineering desktop |
| ge-shopfloor-lockdown | ge.com | Shop floor (locked) |
| ge-shopfloor-mce | ge.com | Shop floor (MCE) |
Network Configuration
- PXE server static IP:
172.16.9.1/24 - DHCP range:
172.16.9.10-172.16.9.100 - Lease time: 12 hours
- DNS:
8.8.8.8(passed to clients, not used by server) - Firewall: UFW deny-by-default, allow 67/udp 69/udp 80/tcp 445/tcp 4433/tcp 9009/tcp
Samba Shares
| Share | Path | Purpose |
|---|---|---|
| winpeapps | /srv/samba/winpeapps | WinPE deployment images |
| clonezilla | /srv/samba/clonezilla | Clonezilla disk backup images |
| blancco-reports | /srv/samba/blancco-reports | Blancco erasure reports (auto) |
| enrollment | /srv/samba/enrollment | GCCH bulk enrollment packages |
| image-upload | /home/pxe/image-upload | Image upload staging area |
All shares use guest access for the isolated network.