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UPDATE: Narrowed down the problem. When a TKL patch contains acpid (specifically acpid_1.0.4--5ubuntu9.3_i386.deb), the build gives a long stream of errors like
Failed to read file turnkey-mediawiki-2009.10-2-hardy-x86.rootfs/proc/irq/9/smp_affinity, creating empty file
Failed to read file turnkey-mediawiki-2009.10-2-hardy-x86.rootfs/proc/kallsyms, creating empty file
The build ultimately fails with
Failed to read file turnkey-mediawiki-2009.10-2-hardy-x86.rootfs/proc/kcore, creating empty file
Failed to read file turnkey-mediawiki-2009.10-2-hardy-x86.rootfs/proc/key-users, creating empty file
It fails at 27% completion, with proc-chroot still mounted on /root/turnkey-mediawiki-2009.10-2-hardy-x86.rootfs/proc.
So something about the acpid package seems to be causing tklpatch to try to package up the contents of procfs, which of course is not going to work. I can work around this by installing acpid manually after installation, but I'd rather not. This seems like a bug in tklpatch, but maybe I'm doing something wrong.
UPDATE: I believe this is a bug in tklpatch. We successfully worked around it by creating a tklpatch that adds the acpid .deb and a script to live-installer.d using the overlay/ mechanism. The script invokes dpkg to install the .deb.
I think I know what's happening
What's probably happening is that once you install ACPID, it spawns a daemon which opens /proc and prevents it from being unmounted. That's the reason the build fails.
The solution is for tklpatch to kill any process that is opening /proc before it umounts, or at least fail if it can't umount. Not sure why it doesn't.
In the meantime, one workaround you could try is to kill your daemon in the conf/post-debs script.
I talked to my Debian gurus, and ...
The best suggestion I've seen is:
That would prevent autostarting any daemons and avoid the need for ad-hoc process killing.
EDIT: An even more principled solution might be to use policy-rc.d to prevent any daemons from launching:
That's probably the way to go
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