sync: auto-sync from HOWARD-HOME at 2026-06-02 10:59:15

Author: Howard Enos
Machine: HOWARD-HOME
Timestamp: 2026-06-02 10:59:15

session-logs/2026-06-02-session.md

@@ -165,3 +165,34 @@ Attempted to forward the email to howard@azcomputerguru.com via Graph `/messages
 ### Reference (this update)
 - M365 tenant azcomputerguru.com (ce61461e-81a0-4c84-bb4a-7b354a9a356d); GuruProtect/INKY (shared.outlook.inky.com) behind Outlook SafeLinks (nam11.safelinks.protection.outlook.com).
 - /mailbox skill; vault msp-tools/claude-msp-access-graph-api.sops.yaml; related security todo 10536f07.
+
+## Update: 17:58 PT — Unraid bzfirmware checksum boot failure (infra)
+
+### Session Summary
+Howard brought in an Unraid server (Dell-monitored box, Generic 8GB USB flash boot) that halts at boot with `bzfirmware checksum error - press ENTER key to reboot...`. Reviewed a photo of the console (Image #5). Diagnosed the failure: Unraid verifies each boot file (bzimage, bzroot, bzroot-gui, bzmodules, bzfirmware) against a stored SHA256 before mounting the OS. bzimage/bzroot/bzroot-gui/bzmodules all passed; only `bzfirmware` failed its checksum, so the OS never loads and the box reboots in a loop.
+
+Confirmed the flash drive itself is healthy at the filesystem layer: console shows `/dev/sda1` detected with label UNRAID, and `fsck.fat 4.2` ran clean (758 files, no FAT errors). The corruption is isolated to the bytes of the `bzfirmware` file, not the FAT structure. Pressing ENTER only reboots into the same error — it does not self-heal.
+
+Provided the remediation procedure: power off, pull USB, back up the entire stick on a Windows PC (critical: the `config/` folder holding super.dat disk assignments, the *.key license, shares, and network settings), download the exact matching Unraid version zip from unraid.net, then overwrite only the `bz*` files (+ their `.sha256`) on the USB while leaving `config/` untouched. Boot should then verify and the array should come up with existing assignments intact.
+
+Flagged that a single corrupt file on a cheap 8GB generic stick is a common early sign of a failing flash drive (the #1 wear item on Unraid). If the error recurs, plan a USB migration to a quality stick (new GUID requires a free self-service license transfer/replacement key at unraid.net, allowed once per 12 months).
+
+### Key Decisions
+- Replace all `bz*` OS files rather than just `bzfirmware`, to guarantee version consistency and avoid kernel/module/firmware mismatch.
+- Preserve the existing `config/` folder verbatim — only the OS files are refreshed, so disk assignments and license survive without a license transfer.
+- Match the downloaded zip to the exact installed Unraid version before proceeding (asked Howard to confirm server/client/version so we grab the right release).
+
+### Problems Encountered
+- bzfirmware checksum mismatch on the Unraid boot USB → fix by overwriting the corrupt `bz*` files from a matching-version Unraid zip; back up `config/` first.
+
+### Configuration Changes
+- `.claude/current-mode` set to `infra`.
+
+### Pending / Incomplete Tasks
+- Confirm which client/server this Unraid box belongs to and the exact installed Unraid version, then download the matching zip and refresh the `bz*` files.
+- Watch for recurrence — if bzfirmware corrupts again, migrate to a new USB and process a license transfer.
+
+### Reference Information
+- Boot device: /dev/sda1, label UNRAID, Generic Flash Disk 8GB (8.05 GB / 7.50 GiB).
+- Unraid downloads: https://unraid.net (current + previous releases).
+- Files to refresh on USB: bzimage, bzroot, bzroot-gui, bzmodules, bzfirmware (+ matching .sha256 each). Do NOT touch config/.