---
name: iso-build
description: Build the current Clawdie ISO image on the FreeBSD host from this repo, using the default tmux window workflow (`clawdie:3` / `iso`), repo-local tmp/ caches, step-by-step preflight, and the current operator-USB validation expectations.
---

# iso-build

Use this skill for the normal FreeBSD host build path from the checked-out
`clawdie-iso` repo. This is the current repo-local operator workflow, not the
older “clone elsewhere and publish to nginx” flow.

Only run an ISO build when the operator explicitly assigns it. If the task is
planning, docs, package-list edits, or static inspection only, do not build.

## Current operator-USB expectations

- Default validation image size: `28G`
- Live browser: Firefox, not Chromium
- SDDM interactive login as `clawdie`; no live autologin
- `CLAWDIESEED` exists as FAT32 slice 3 for post-flash, pre-boot seed import
- Live CLI policy: ship `codex`, `pi`, `gemini`; do not ship `claude`
- Operator editors: `mousepad`, `geany`, and `micro`
- Hardware/custom-ISO report collector: `hw-report`
- Vulkan diagnostic tool: `vulkaninfo` from `vulkan-tools`; Zed remains deferred
  until Intel+AMD Vulkan are proven on hardware
- X blanking / DPMS disabled; NumLock off
- Power policy: `powerdxx` + `C3`, not `Cmax`
- Panel/runtime checks include `mixer`; `clipman` is intentionally dropped from
  the panel pending a D-Bus root-cause (see `doc/XFCE-PANEL-BUGS-HANDOFF.md`)
- Final graphical validation requires real hardware, not bhyve/nested VM only

## Workspace names

Keep the real paths as-is, but speak about them clearly:

- `tmp/output` = output image artifacts
- `tmp/cache` = build cache
- `tmp/cache/mnt` = mounted work image
- `tmp/cache/FreeBSD-*.img` = cached memstick base image
- `tmp/packages` = fetched package archives

## Manifest contract

The build workflow should emit or hand off `clawdie.iso.build.v1` results under
`tmp/colibri/iso-build/` when Colibri ingestion is part of the task. The image
itself also embeds `/usr/local/share/clawdie-iso/build-manifest.json` for live
runtime inspection. See `docs/ISO-MANIFESTS.md` for the schema fields and path
conventions.

## Preconditions

- Run on the FreeBSD build host, from the repo root
- Prefer `tmux` for long builds
- Use an elevated shell in the tmux pane so the build command itself runs
  without a `sudo` prefix
- Run one command at a time; do not hide failures behind chained shell commands
- Fetch before reporting remote state or starting a build
- If disk is tight, the image build was interrupted, or `tmp/cache/mnt` is
  still mounted, use `iso-build-cleanup` first

## Default tmux workflow

This is the default operator workflow and should be treated as the normal path.

### 1. Ensure the dedicated ISO window exists

```sh
tmux list-windows -t clawdie
```

If `clawdie:3` / `iso` does not exist, create it:

```sh
tmux new-window -t clawdie:3 -n iso
```

### 2. Inspect the pane before reusing it

```sh
tmux capture-pane -pt clawdie:3.1 -S -30
ps auxww | egrep '[b]uild.sh|[s]cript -q tmp/operator-usb-.*-build.log'
```

If a build is still active, do not clobber it. Stop or wait deliberately.

### 3. Start clean after a failed attempt

When reusing the pane from a failed attempt:

- stop the foreground command with `Ctrl-C`
- return to repo root
- clear the pane with `Ctrl-L`
- emit a marker line so the next run is easy to identify in scrollback

Suggested marker:

```sh
echo "test build nr: $(ls tmp/operator-usb-*-build.log 2>/dev/null | wc -l | tr -d ' ') date: $(date +%d.%b.%y) ver: $(git rev-parse --short HEAD)"
```

### 4. Use the standard build command in `3:iso`

```sh
/usr/bin/script -q tmp/operator-usb-$(git rev-parse --short HEAD)-build.log ./build.sh --skip-memstick-fetch --live-default-password
```

If the operator explicitly asked for a baked SSH key, append:

```sh
--ssh-key '<public key>'
```

## Preflight

Run these before starting a build, one command at a time:

```sh
git fetch origin
git status --short --branch
git log --oneline -5
git rev-parse --short HEAD
df -h /home/clawdie /
du -xh -d 2 tmp | sort -h | tail -n 40
ls -lh tmp/output
du -xh -d 1 tmp/cache | sort -h
```

If you see stale mounts, md devices, or `work.img` still attached, stop and
switch to `iso-build-cleanup`.

### Colibri artifact preflight

The operator USB uses Colibri as its lightweight live control plane. The ISO
build stages FreeBSD-native Colibri artifacts from `/home/clawdie/ai/colibri`;
it does **not** build Rust while the image is mounted. Validation builds should
ship `colibri_daemon_enable=YES`; the rc.d service starts after LOGIN and must
not block SDDM/XFCE startup.

Build Colibri on the FreeBSD/OSA host, not on Debian/Linux. Do not cross-ship
from debby unless the native OSA build fails.

Run this before the ISO build:

```sh
cd /home/clawdie/ai/colibri
git fetch origin
git status --short --branch
git pull --ff-only
cargo build --workspace --release

ls -lh target/release/colibri-daemon \
       target/release/colibri \
       target/release/colibri-test-agent \
       target/release/colibri-mcp

file target/release/colibri-daemon \
     target/release/colibri \
     target/release/colibri-test-agent \
     target/release/colibri-mcp

# Optional in the staging script, but desired for this operator USB target.
if [ -x target/release/colibri-tui ]; then
  ls -lh target/release/colibri-tui
  file target/release/colibri-tui
else
  echo "WARN: optional colibri-tui artifact is missing"
fi

target/release/colibri --help | head
```

Then return to the ISO repo and run syntax/preflight checks:

```sh
cd /home/clawdie/ai/clawdie-iso
git fetch origin
git status --short --branch
git pull --ff-only
sh -n build.sh
sh -n scripts/stage-colibri-iso.sh
```

Important cleanup timing: **do not run `cargo clean` immediately after the
Colibri build.** The ISO preflight/build consumes `/home/clawdie/ai/colibri/target/release`.
Only clean Colibri after the ISO build or after deciding those artifacts are no
longer needed:

```sh
cd /home/clawdie/ai/colibri
cargo clean
rm -rf /tmp/colibri-*
```

`colibri-mcp` is part of the out-of-the-box operator USB. `colibri-tui` is
optional in the staging script, but desired for this operator USB target and
should be verified with the required binaries.

### Deployed-system Clawdie service boundary

`service clawdie` is reserved for installed disk/server targets, but the current
operator USB does not stage a `clawdie` rc.d service or mini-binary. The live USB
uses `colibri_daemon` directly. Add deployed-system service packaging only after
the real persistent host service implementation is chosen; do not repurpose the
old Colibri-side mini-binary as the final service by default.

### Next build: carry the XFCE operator-USB fixes

The next operator-USB image must retain the proven XFCE/live-GUI fixes
(`PLAN-OPERATOR-USB-NEXT.md`, `doc/AMD-ASUS-XFCE-LIVE-USB-FINDINGS.md`):

- **SDDM remains the supported live display manager** — load-bearing; do not
  replace without equivalent real-hardware proof for Intel + AMD live GUI boot.
- **`clawdie-live-gpu`** pre-SDDM rc.d KMS pick (conservative; NVIDIA/AMD safe).
- **Hardened USB-root power policy** (`b9290ab`): `powerdxx`, C3 C-state default,
  `hw.usb.no_suspend=1`, boot-time `power_profile`.
- Base fixes already landed: resolver bootstrap, internal-audio preference,
  touchpad XInput guards, loader branding, hardware-report capture.

Real hardware remains final proof for XFCE/session/input/audio — bhyve and
static image inspection are build gates only.

## Choose fetch mode

Use the lightest safe flag:

- `./build.sh`
  Fresh fetch of memstick + packages

- `./build.sh --skip-memstick-fetch`
  Reuse the cached FreeBSD memstick image, but refresh packages

- `./build.sh --skip-fetch`
  Reuse both memstick and package caches; use only when both caches are
  known-good

For the current operator workflow, the default is:

```sh
./build.sh --skip-memstick-fetch --live-default-password
```

## What to watch

Normal progress moves through:

1. Fetch/update package repo
2. Prepare Clawdie-AI offline tarball
3. Prepare work image
4. Inject payload
5. Write output image

Watch for these common blockers:

- `pkg-static ... conflicts with ...`
- `Write error` while extracting a package
- `database is locked` after a package failure
- `Not a directory` under `tmp/cache/mnt/usr/local/share/clawdie-iso/...`
- `mdconfig` devices left attached after interruption
- wrong ownership on `/opt/clawdie/npm-global`

If the build is interrupted or the work image gets wedged, stop and use
`iso-build-cleanup` before retrying.

## Output checks

After a successful build:

```sh
ls -lh tmp/output
find tmp/output -maxdepth 1 -type f -ls
```

Typical artifacts are:

- raw `.img`
- compressed `.img.xz`
- matching `.img.xz.sha256`

Public/test artifact names should include the source commit suffix.

## Static image expectations

Mounted-image checks should confirm:

- `firefox` is installed on the live rootfs
- `chromium` is not installed on the live rootfs
- `codex`, `pi`, and `gemini` are present
- `claude` is absent
- `mousepad`, `geany`, and `micro` are present
- `hw-report` and its desktop launcher are present
- `hw-probe`, `smartmontools`, `lscpu`, `lsblk`, `hwstat`, and `usbhid-dump` are present
- `libinput`, `xinput`, `xrandr`, and `glxinfo` are present for input/video diagnostics
- `vulkaninfo` is present for Intel+AMD Vulkan checks before any future Zed move
  to live rootfs
- `sudo` is absent
- live privileged commands use `mdo -u root ...`
- `CLAWDIESEED` exists as slice 3
- branded Start icon (`/usr/local/share/clawdie-iso/icons/clawdie-start.png`) and
  wallpaper (`/usr/local/share/clawdie-iso/wallpapers/clawdie-operator-bg.png`)
  are installed
- X blanking / DPMS are disabled
- NumLock is forced off
- `powerdxx` is installed and the live policy uses `C3`
- panel checks cover `mixer`; `clipman` is intentionally absent (dropped pending
  root-cause — see `doc/XFCE-PANEL-BUGS-HANDOFF.md`)

If you plan another rebuild soon, keep:

- `tmp/cache/FreeBSD-15.0-RELEASE-amd64-memstick.img`
- `tmp/cache/FreeBSD-15.0-RELEASE-amd64-memstick.img.SHA256`
- `tmp/packages/`
- `tmp/npm-globals/`

## Retry guidance

Use these rules:

- build failed after package refresh but memstick cache is fine:
  retry with `--skip-memstick-fetch`
- build failed because package cache looks wrong:
  retry without `--skip-fetch`
- build failed after leaving mounts, md devices, or a large stale `work.img`:
  run `iso-build-cleanup`, then retry