From 0decb39b17bf5f58ef42183e4823ff4cbbdc5870 Mon Sep 17 00:00:00 2001
From: "Aaron D. Lee" <aaron.daniel.lee@mgial.com>
Date: Thu, 8 Jan 2026 12:00:47 -0500
Subject: [PATCH] Move filesystem expansion to first-boot wizard

Instead of a hidden systemd service, expand the filesystem
visibly during the first-boot wizard so users can see it
happening.

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>
---
 rpi/first-boot-wizard.sh | 22 ++++++++++++++++++++++
 rpi/pull-image.sh        | 31 -------------------------------
 2 files changed, 22 insertions(+), 31 deletions(-)

diff --git a/rpi/first-boot-wizard.sh b/rpi/first-boot-wizard.sh
index 59dc4fb..8f1fe47 100755
--- a/rpi/first-boot-wizard.sh
+++ b/rpi/first-boot-wizard.sh
@@ -53,6 +53,28 @@ echo ""
 
 gum confirm "Ready to begin setup?" || exit 0
 
+# =============================================================================
+# Step 0: Expand Filesystem
+# =============================================================================
+
+clear
+gum style \
+  --foreground 212 --bold \
+  "Expanding filesystem..."
+echo ""
+
+# Get current and total size
+ROOT_DEV=$(findmnt -n -o SOURCE /)
+CURRENT_SIZE=$(df -h / | awk 'NR==2 {print $2}')
+gum style --foreground 245 "Current size: $CURRENT_SIZE"
+
+# Run resize2fs with a spinner
+gum spin --spinner dot --title "Expanding to fill SD card..." -- sudo resize2fs "$ROOT_DEV" 2>/dev/null
+
+NEW_SIZE=$(df -h / | awk 'NR==2 {print $2}')
+gum style --foreground 82 "✓ Expanded to: $NEW_SIZE"
+sleep 1
+
 # =============================================================================
 # Configuration Variables
 # =============================================================================
diff --git a/rpi/pull-image.sh b/rpi/pull-image.sh
index 3b663d3..b290aa6 100755
--- a/rpi/pull-image.sh
+++ b/rpi/pull-image.sh
@@ -123,37 +123,6 @@ else
     echo -e "${GREEN}  Rootfs already ~16GB${NC}"
 fi
 
-# ============================================================================
-# Re-enable auto-expand for release image
-# ============================================================================
-echo
-echo -e "${YELLOW}Re-enabling auto-expand for release...${NC}"
-TEMP_ROOT=$(mktemp -d)
-sudo mount "$ROOT_PART" "$TEMP_ROOT"
-
-# Create the resize service that runs on first boot
-sudo tee "$TEMP_ROOT/etc/systemd/system/rpi-resizerootfs.service" > /dev/null <<'RESIZE_EOF'
-[Unit]
-Description=Resize root filesystem to fill SD card
-After=local-fs.target
-
-[Service]
-Type=oneshot
-ExecStart=/bin/bash -c 'resize2fs $(findmnt -n -o SOURCE /) && systemctl disable rpi-resizerootfs.service && rm -f /etc/systemd/system/rpi-resizerootfs.service'
-ExecStartPost=/bin/systemctl daemon-reload
-
-[Install]
-WantedBy=multi-user.target
-RESIZE_EOF
-
-# Enable the service
-sudo mkdir -p "$TEMP_ROOT/etc/systemd/system/multi-user.target.wants"
-sudo ln -sf /etc/systemd/system/rpi-resizerootfs.service "$TEMP_ROOT/etc/systemd/system/multi-user.target.wants/rpi-resizerootfs.service"
-
-sudo umount "$TEMP_ROOT"
-rmdir "$TEMP_ROOT"
-echo -e "${GREEN}  Auto-expand service installed${NC}"
-
 # ============================================================================
 # Pull image
 # ============================================================================