[Bug 277828] 15-CURRENT installation fails when /usr is on seperate UFS volume

From: <bugzilla-noreply_at_freebsd.org>
Date: Wed, 20 Mar 2024 07:54:43 UTC
https://bugs.freebsd.org/bugzilla/show_bug.cgi?id=277828

            Bug ID: 277828
           Summary: 15-CURRENT installation fails when /usr is on seperate
                    UFS volume
           Product: Base System
           Version: 15.0-CURRENT
          Hardware: Any
                OS: Any
            Status: New
          Severity: Affects Some People
          Priority: ---
         Component: bin
          Assignee: bugs@FreeBSD.org
          Reporter: michaelo@FreeBSD.org

I have created a UEFI guest with vm-bhyve on 13.3-STABLE from 77814c959. 50 GB
disk space (virtio-blk) with
FreeBSD-15.0-CURRENT-amd64-20240314-220ee18f1964-268793-disc1.iso.

Selected the following (simplified) disk layout:
>             ┌─────────────────┤Partition Editor├──────────────────┐
>             │ Please review the disk setup. When complete, press  │
>             │ the Finish button.                                  │
>             │                                                     │
>             │                                                     │
>             │ ┌─────────────────────────────────────────────────┐ │
>             │ │vtbd0       50 GB     GPT                        │ │
>             │ │  vtbd0p1   260 MB    efi             /boot/efi  │ │
>             │ │  vtbd0p2   4.0 GB    freebsd-ufs     /          │ │
>             │ │  vtbd0p3   8.0 GB    freebsd-swap    none       │ │
>             │ │  vtbd0p4   38 GB     freebsd-ufs     /usr       │ │
>             │ │                                                 │ │
>             │ │                                                 │ │
>             │ │                                                 │ │
>             │ │                                                 │ │
>             │ │                                                 │ │
>             │ └─────────────────────────────────────────────────┘ │
>             ├─────────────────────────────────────────────────────┤
>             │[Create] [Delete] [Modify] [Revert] [ Auto ] [Finish]│
>             └─────────────────────────────────────────────────────┘

continue with the installation and you will receive:
>                    ┌─────────┤Archive Extraction├─────────┐
>                   ┌─────────────┤Extract Error├────────────┐
>                   │ Error while extracting base.txz: Can't │
>                   │ create 'etc/ssl/untrusted/c47d9980.0'  │
>                   │                                        │
>                   ├────────────────────────────────────────┤
>                   │                [  OK  ]                │
>                   └────────────────────────────────────────┘
>                    │
>                    └──────────────────────────────────────┘

as soon as /usr is not on a separate partition the installation succeeds.

I have also tried the following sizes:
>             ┌─────────────────┤Partition Editor├──────────────────┐
>             │ Please review the disk setup. When complete, press  │
>             │ the Finish button.                                  │
>             │                                                     │
>             │                                                     │
>             │ ┌─────────────────────────────────────────────────┐ │
>             │ │vtbd0       50 GB     GPT                        │ │
>             │ │  vtbd0p1   260 MB    efi             /boot/efi  │ │
>             │ │  vtbd0p2   12 GB     freebsd-ufs     /          │ │
>             │ │  vtbd0p3   4.0 GB    freebsd-swap    none       │ │
>             │ │  vtbd0p4   12 GB     freebsd-ufs     /usr       │ │
>             │ │                                                 │ │
>             │ │                                                 │ │
>             │ │                                                 │ │
>             │ │                                                 │ │
>             │ │                                                 │ │
>             │ └─────────────────────────────────────────────────┘ │
>             ├─────────────────────────────────────────────────────┤
>             │[Create] [Delete] [Modify] [Revert] [ Auto ] [Finish]│
>             └─────────────────────────────────────────────────────┘

Same result. It does not seems to be a size issue, but some other problem.

I am trying to replicate a VM for Bug 277804 with the same UFS setup. I would
expect it to work as it did when I installed the original machine with 11/12
five years so.

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