pull-image: Auto-resize rootfs to 16GB before pull

- Unmounts and resizes partition to exactly 16GB
- Handles both shrinking (large cards) and expanding (small cards)
- Disables Pi OS auto-expand service
- Consistent image size regardless of source SD card
- 16GB = minimum disk requirement = image size

🤖 Generated with [Claude Code](https://claude.com/claude-code)

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>

rpi/pull-image.sh

@@ -1,12 +1,18 @@
 #!/bin/bash
 # Pull Raspberry Pi image from SD card (after setup)
-# Only pulls the actual used partition space, not the entire SD card
+# Resizes rootfs to 16GB for consistent image size, then pulls
 #
 # Usage: ./pull-image.sh <device> <output.img.zst>
 # Example: ./pull-image.sh /dev/sdb stegasoo-rpi-4.1.5.img.zst
 
 set -e
 
+RED='\033[0;31m'
+GREEN='\033[0;32m'
+YELLOW='\033[1;33m'
+BOLD='\033[1m'
+NC='\033[0m'
+
 if [ $# -ne 2 ]; then
     echo "Usage: $0 <device> <output.img.zst>"
     echo "Example: $0 /dev/sdb stegasoo-rpi-4.1.5.img.zst"
@@ -16,25 +22,139 @@ fi
 DEVICE="$1"
 OUTPUT="$2"
 
-if [ ! -b "$DEVICE" ]; then
+# Check for root
-    echo "Error: Device not found: $DEVICE"
+if [ "$EUID" -ne 0 ]; then
+    echo -e "${RED}Error: Must run as root (sudo)${NC}"
     exit 1
 fi
 
-echo "Device info:"
+if [ ! -b "$DEVICE" ]; then
+    echo -e "${RED}Error: Device not found: $DEVICE${NC}"
+    exit 1
+fi
+
+echo -e "${BOLD}Device info:${NC}"
 lsblk "$DEVICE"
 echo
 
-# Get partition info
+# Find partitions
-echo "Partition table:"
+if [ -b "${DEVICE}1" ]; then
-sudo parted -s "$DEVICE" unit s print
+    BOOT_PART="${DEVICE}1"
+    ROOT_PART="${DEVICE}2"
+elif [ -b "${DEVICE}p1" ]; then
+    BOOT_PART="${DEVICE}p1"
+    ROOT_PART="${DEVICE}p2"
+else
+    echo -e "${RED}Error: Could not find partitions${NC}"
+    exit 1
+fi
+
+# Unmount any mounted partitions
+echo -e "${YELLOW}Unmounting partitions...${NC}"
+umount "$BOOT_PART" 2>/dev/null || true
+umount "$ROOT_PART" 2>/dev/null || true
+
+# ============================================================================
+# Resize rootfs to 16GB
+# ============================================================================
+echo
+echo -e "${BOLD}Checking partition size...${NC}"
+
+# Get current partition size in bytes
+CURRENT_SIZE=$(blockdev --getsize64 "$ROOT_PART")
+TARGET_BYTES=$((16 * 1024 * 1024 * 1024))  # 16GB in bytes
+CURRENT_GB=$(echo "scale=2; $CURRENT_SIZE / 1073741824" | bc)
+
+echo "  Current rootfs size: ${CURRENT_GB}GB"
+
+if [ "$CURRENT_SIZE" -gt "$TARGET_BYTES" ]; then
+    echo -e "${YELLOW}Resizing rootfs to 16GB...${NC}"
+
+    # Get boot partition end in sectors
+    BOOT_END=$(parted -s "$DEVICE" unit s print | grep "^ 1" | awk '{print $3}' | tr -d 's')
+
+    # Calculate 16GB in sectors (512 byte sectors)
+    ROOT_SIZE_SECTORS=33554432
+    ROOT_END=$((BOOT_END + ROOT_SIZE_SECTORS))
+
+    # SHRINKING: filesystem first, then partition
+    echo "  Checking filesystem..."
+    e2fsck -f -y "$ROOT_PART" 2>/dev/null || true
+
+    # Shrink filesystem to 15.5GB (leave room for partition overhead)
+    echo "  Shrinking filesystem to 15500M..."
+    resize2fs "$ROOT_PART" 15500M
+
+    # Delete and recreate partition 2 with 16GB size
+    echo "  Shrinking partition to 16GB..."
+    parted -s "$DEVICE" rm 2
+    parted -s "$DEVICE" mkpart primary ext4 $((BOOT_END + 1))s ${ROOT_END}s
+
+    # Refresh partition table
+    partprobe "$DEVICE"
+    sleep 2
+
+    # Expand filesystem to fill the partition exactly
+    echo "  Expanding filesystem to fill partition..."
+    e2fsck -f -y "$ROOT_PART" 2>/dev/null || true
+    resize2fs "$ROOT_PART"
+
+    echo -e "${GREEN}  Rootfs resized to 16GB${NC}"
+elif [ "$CURRENT_SIZE" -lt "$TARGET_BYTES" ]; then
+    echo -e "${YELLOW}  Rootfs is smaller than 16GB - expanding...${NC}"
+
+    # Get boot partition end in sectors
+    BOOT_END=$(parted -s "$DEVICE" unit s print | grep "^ 1" | awk '{print $3}' | tr -d 's')
+    ROOT_SIZE_SECTORS=33554432
+    ROOT_END=$((BOOT_END + ROOT_SIZE_SECTORS))
+
+    # EXPANDING: partition first, then filesystem
+    parted -s "$DEVICE" rm 2
+    parted -s "$DEVICE" mkpart primary ext4 $((BOOT_END + 1))s ${ROOT_END}s
+
+    partprobe "$DEVICE"
+    sleep 2
+
+    e2fsck -f -y "$ROOT_PART" 2>/dev/null || true
+    resize2fs "$ROOT_PART"
+
+    echo -e "${GREEN}  Rootfs expanded to 16GB${NC}"
+else
+    echo -e "${GREEN}  Rootfs already ~16GB${NC}"
+fi
+
+# ============================================================================
+# Disable auto-expand on first boot
+# ============================================================================
+echo
+echo -e "${YELLOW}Disabling auto-expand...${NC}"
+TEMP_ROOT=$(mktemp -d)
+mount "$ROOT_PART" "$TEMP_ROOT"
+
+# Remove resize2fs_once service if it exists
+rm -f "$TEMP_ROOT/etc/init.d/resize2fs_once"
+rm -f "$TEMP_ROOT/etc/rc3.d/S01resize2fs_once"
+
+# Disable the systemd resize service
+rm -f "$TEMP_ROOT/etc/systemd/system/multi-user.target.wants/rpi-resizerootfs.service"
+
+umount "$TEMP_ROOT"
+rmdir "$TEMP_ROOT"
+echo -e "${GREEN}  Auto-expand disabled${NC}"
+
+# ============================================================================
+# Pull image
+# ============================================================================
+echo
+echo -e "${BOLD}Partition table:${NC}"
+parted -s "$DEVICE" unit s print
 echo
 
 # Get the end of the last partition (partition 2 = rootfs)
-END_SECTOR=$(sudo parted -s "$DEVICE" unit s print | grep "^ 2" | awk '{print $3}' | tr -d 's')
+END_SECTOR=$(parted -s "$DEVICE" unit s print | grep "^ 2" | awk '{print $3}' | tr -d 's')
 
 if [ -z "$END_SECTOR" ]; then
-    echo "Error: Could not determine partition 2 end sector"
+    echo -e "${RED}Error: Could not determine partition 2 end sector${NC}"
     exit 1
 fi
 
@@ -43,8 +163,8 @@ TOTAL_SECTORS=$((END_SECTOR + 2048))
 TOTAL_BYTES=$((TOTAL_SECTORS * 512))
 TOTAL_GB=$(echo "scale=2; $TOTAL_BYTES / 1073741824" | bc)
 
-echo "Image will be approximately ${TOTAL_GB}GB (${TOTAL_SECTORS} sectors)"
+echo -e "Image size: ${YELLOW}~${TOTAL_GB}GB${NC} (${TOTAL_SECTORS} sectors)"
-echo "Output file: $OUTPUT"
+echo -e "Output: ${YELLOW}$OUTPUT${NC}"
 echo
 
 read -p "Proceed with image pull? [Y/n] " confirm
@@ -53,24 +173,24 @@ if [[ "$confirm" =~ ^[Nn]$ ]]; then
     exit 1
 fi
 
-echo "Pulling image..."
+echo
+echo -e "${GREEN}Pulling image...${NC}"
 echo
 
 # Use pv if available for progress, otherwise fallback to dd status
 if command -v pv &> /dev/null; then
-    sudo dd if="$DEVICE" bs=512 count=$TOTAL_SECTORS 2>/dev/null | \
+    dd if="$DEVICE" bs=512 count=$TOTAL_SECTORS 2>/dev/null | \
         pv -s $TOTAL_BYTES | \
         zstd -T0 -3 > "$OUTPUT"
 else
-    sudo dd if="$DEVICE" bs=512 count=$TOTAL_SECTORS status=progress | \
+    dd if="$DEVICE" bs=512 count=$TOTAL_SECTORS status=progress | \
         zstd -T0 -3 > "$OUTPUT"
 fi
 
 echo
-echo "Done! Image saved to: $OUTPUT"
+echo -e "${GREEN}Done!${NC} Image saved to: $OUTPUT"
 ls -lh "$OUTPUT"
 
-# Show verification info
 echo
-echo "To verify, you can check the image with:"
+echo "To verify:"
 echo "  zstdcat $OUTPUT | fdisk -l /dev/stdin"