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Page history last edited by PBworks 15 years, 8 months ago



Clean USB pivot_root for WGT634U and OpenWrt (Kamikaze).


The general idea is to create a root filesystem on a usb storage device / partition, via standard OpenWrt install. Then to flash the wgt634u with a squashfs based image that has the requisite kernel modules to recognize USB storage devices and their partitions and to mount a FAT or ext2 filesystem (other are possible) as the root filesystem (via pivot_root) in /etc/preinit. The candidate usb file systems are tested for some basic directories and files before a pivot_root is done from the squashfs (which becomes /rom) to /usb (which becomes, duh, /). No jffs filesystem is ever mounted. Under this paradigm, the on-board flash is never written to during normal device operation. I take /tmp out of RAM (I opt for RAM, not for fast /tmp). /etc/inittab is altered to run /etc/init.d/rcK which unmounts filesystems and prevents unclean restarts.


In the case where a USB storage device with a compatibale filesystem is not present at initialization, /etc/preinit will keep scanning /dev/scsi (or some specified directory) for a suitable host, bus, target, lun, part combination. When a mountable filesystem is found, the filesystem type is detected (for fat and ext2) and a filesystem check is run, before the target is mounted read & write. The kernel didn't panic when I removed one of my flash sticks (with the root fs). Although, the device did not recover when the stick was reinserted as it looks like when it was reinserted the filesystems on the stick got new device filenames.


This has been tested on: OpenWrt (Kamikaze) releases 3535.


  • Get fresh source & configure it for WGT634U w/ minimal modules for USB storage host and ext2 & FAT filesystems:


svn co -r 3535 https://svn.openwrt.org/openwrt/trunk/

cd trunk/openwrt

make menuconfig


  • Select '*' (not 'M'!) for the following items:

Target System (Broadcom BCM47xx/53xx [2.6])

OpenWrt Package Selection --->

Utilities --->

lsusb # very useful

FileSystems related --->

dosfstools # for mkdosfs

e2fsprogs # for e2fsck and mke2fs

util-linux --->

fdisk # very useful

swap-utils # for swap, untested

Kernel Configuration / Device Support --->

Filesystems support --->

kmod-fs-vfat # for vfat fs support

kmod-fs-ext2 # for ext2 fs support

# others? untested but useful!

Native Language support --->

kmod-nls-base # for fat and vfat


# select the correct one for you

USB support --->

kmod-usb-core # need usb host support




kmod-usb-storage # for mass storage devices



  • Save your configuration. Build it with:





  • Install the squashfs image in bin. For 3535 it is openwrt-wgt634u-2.6-squashfs.bin in the bin directory. I did it via CFE and a serial console. Like so (your hwaddr, ipaddr, etc. will differ as will the bytes read and written - see the WGT634U hardware page at openwrt.org):


CFE> ifconfig eth0 -auto

et0: link down

Device eth0: hwaddr 00-00-C0-FF-EE-00, ipaddr, mask

gateway, nameserver, domain foo.bar.

*** command status = 0

CFE> flash -noheader flash0.os

Reading Done. 1806336 bytes read

Programming...done. 1806336 bytes written

*** command status = 0


  • Reboot the unit. It will boot kernel from flash and root from squashfs. Then it will run firstboot and create a complete jffs filesystem in flash for 'permanent storage'. Plug in a usb storage device (I used a couple of old (backed up) 16 and 32 MB flash sticks - all with a single filesystem on them). Wait while the usb drivers find, recognize and initialize the storage device. (What happens when it doesn't work? I don't know, haven't had that happen with tested devices.) On the serial console, I saw the following to signify a '32MB' flash stick device was working:


usb 2-1: new full speed USB device using ohci_hcd and address 3

usb 2-1: configuration #1 chosen from 1 choice

scsi1 : SCSI emulation for USB Mass Storage devices

Vendor: Generic Model: USB Flash Drive Rev: %z!Y

Type: Direct-Access ANSI SCSI revision: 02

SCSI device sda: 64128 512-byte hdwr sectors (33 MB)

sda: Write Protect is off

sda: assuming drive cache: write through

SCSI device sda: 64128 512-byte hdwr sectors (33 MB)

sda: Write Protect is off

sda: assuming drive cache: write through

/dev/scsi/host1/bus0/target0/lun0: p1

sd 1:0:0:0: Attached scsi removable disk sda


  • Note the device it reports (in my case: /dev/scsi/host1/bus0/target0/lun0: p1 - which is /dev/scsi/host1/bus0/target0/lun0/part1). On 3554 it was /dev/scsi/host0 not /dev/scsi/host1. (Might have to do with module load order?) Do something clever in your serial console shell:





  • Optional: Create a new filesystem (and possibly a partition table) on the device. I do this. Mostly as another check to make sure all the utilities to maintain a filesystem are installed. W/ fdisk, I initialize a new partition table and create a new partition. That partition's type should be 83 if you intend to use ext2 or one of the FAT types (types depending on device size?) for a FAT filesystem. Make filesystems (mke2fs $usb_root_device OR mkdosfs $usb_root_device).



  • Mount the filesystem on the storage device. Make a /usb directory to mount your storage device:


mkdir -p /usb


  • Mount it. To test that your mount auto type checking is working, DO NOT specify the filesystem type. If mount cannot autodetermine it now, it will not be able to at boot.


mount $usb_root_device /usb



  • Now you need to copy the base filesystem from squashfs and jffs to your usb filesystem. This is tricky for a few reasons: most files in your jffs filesystem are sym links to your read only filesystem, firstboot creates some files that are only on jffs, and you have to do it by hand. I found it is easier to copy from /rom than from /. I did something like:


cd /usb

# directory stubs

mkdir proc

mkdir sys

mkdir dev

mkdir rom

# copy from from squashfs

mkdir bin

cp -a /rom/bin/* bin

mkdir etc

cp -a /rom/etc/* etc

mkdir usr

cp -a /rom/usr/* usr

mkdir lib

cp -a /rom/lib/* lib

mkdir sbin

cp -a /rom/sbin/* sbin

# copy from jffs

mkdir tmp

cp -a /tmp/* tmp

mkdir var

cp -a /var/* var

cp -a /etc/config etc

# do some final preparations on your new root filesystem

chmod oug+rwxt /tmp

# umount some filesystems that the kernel mounts or are required by preinit

# from /rom

cat << EOF >> etc/init.d/S99done


# umount old dev, proc and usbfs

umount /rom/proc/bus/usb

umount /rom/proc

umount /rom/dev



  • To have init unmount filesystems cleanly and remount root filesystem readonly before halting, into etc/init.d/rcK put:




# umount dev, proc, sys and usbfs

usb_root_device=`mount | awk '{ if ($3 == "/") print $1 }'`


echo "unmounting memory based filesystems"

umount /sys

umount /dev/pts

umount /proc/bus/usb


echo "remounting root in read only mode"

mount $usb_root_device / -o remount -o ro


echo "halting system"



  • Make sure you do:


chmod +x etc/init.d/rcK


  • Also, alter inittab to call your kill script:


cat << EOF > inittab



tts/0::askfirst:/bin/ash --login

#tts/1::askfirst:/bin/ash --login



  • Remove anything that could write to flash and clobber CFE (paranoia brick defense precautions):


\rm /usb/bin/firstboot /usb/sbin/mount_root /usb/etc/preinit /usb/sbin/mtd /usb/sbin/jffs2root


  • Once you you are sure you have copied the relevant parts of the filesystem structure, unmount the usb storage device's partition(s). I recommend making a tar image of the usb device (on another machine). This way you can quickly just reformat the device and untar the archive for a fresh OpenWrt install.



  • Now make a new flash image (openwrt-wgt634u-2.6-squashfs.bin) that has a different /etc/preinit (and some other minor paranoia brick defense changes). To do this, go into your build root directory, i.e. trunk/openwrt/build_mipsel/root (where you previously built Kamikaze):


cd trunk/openwrt/build_mipsel/root

# paranoia brick defense precautions

\rm bin/firstboot sbin/mount_root etc/preinit sbin/mtd sbin/jffs2root

# make mount point for usb

mkdir usb


  • Now copy this preinit file to etc/preinit. This is the core of the usb root mount. This loads requisite modules and searches for usb storage (or SCSI more generally) partitions with enough of a filesystem as to appear to be a root file system. Examine this file before you install it. Most people won't need to edit it. Other file systems may be mounted with via /etc/fstab and mount in an /etc/init.d/rcS script later so there is no need to add them to preinit. Download and copy like:


# copy your own preinit to etc/preinit (assumes you have wget)

# in your build root directory (i.e. trunk/openwrt/build_mipsel/root), do

wget -O etc/preinit http://openwrt.pbwiki.com/f/WGT634U_USB_root_preinit

# don't forget to set it executable

chmod +x etc/preinit



  • Build the new image:


cd trunk/openwrt

make target/install


  • Check your image by looking at the tgz counterpart, quickly:


tar -tvzf build_mipsel/linux-2.6-brcm/root.tar.gz | more


  • In particular, make sure ./etc/preinit is the correct size, also verify that (paranoia brick defense) ./bin/firstboot, ./sbin/mount_root, ./sbin/jffs2root and ./sbin/mtd are absent.


  • Flash the image via CFE and tftp. Reboot. Enjoy - never have your system writing to flash again! See stuff below:


root@OpenWrt:/# df

Filesystem 1k-blocks Used Available Use% Mounted on

/dev/scsi/host0/bus0/target0/lun0/part1 31029 4665 24762 16% /


root@OpenWrt:/# mount

(null) on /rom type squashfs (ro)

/dev/scsi/host0/bus0/target0/lun0/part1 on / type ext2 (rw,nogrpid)

none on /proc type proc (rw)

none on /dev type devfs (rw)

none on /dev/pts type devpts (rw)

none on /proc/bus/usb type usbfs (rw)

none on /sys type sysfs (rw)


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