Modified make_img_file.sh so that the vfat partition size is dynamically calculated based on the bzImage size plus an arbitary 20MB added to accommodate the extra files including PDF reports and logs.

board/shredos/genimage_i586.cfg

@@ -12,7 +12,7 @@ image boot.vfat {
                 file autorun.inf            { image = 'autorun.inf' }
         }
 
-        size = 380000000
+size = 74137344
 }
 
 image shredos.img {

board/shredos/make_img_file.sh

@@ -23,6 +23,31 @@ cp "board/shredos/shredos.ico"             "${BINARIES_DIR}/shredos.ico"
 # version.txt is used to help identify the (boot) USB disk
 cp "board/shredos/fsoverlay/etc/shredos/version.txt" "${BINARIES_DIR}/version.txt"        || exit 1
 
+# Determine size of FAT partition based on size of bzImage plus an arbitary 20MB to hold PDF's etc.
+BZIMAGE="${BINARIES_DIR}/bzImage"
+CFG="board/shredos/${MKIMAGE_CFG}"
+OFFSET=20000000
+
+# Get bzImage size in bytes
+if [[ ! -f "$BZIMAGE" ]]; then
+    echo "Error: $BZIMAGE not found"
+    exit 1
+fi
+
+SIZE=$(stat -c %s "$BZIMAGE")
+NEW_SIZE=$((SIZE + OFFSET))
+
+# Update size line in genimage.cfg
+if [[ ! -f "$CFG" ]]; then
+    echo "Error: $CFG not found"
+    exit 1
+fi
+
+sed -i -E "0,/^[[:space:]]*size[[:space:]]*=/{s/^[[:space:]]*size[[:space:]]*=.*/size = ${NEW_SIZE}/}" "$CFG"
+
+echo "Updated size to $NEW_SIZE bytes in $CFG"
+
+# Create the .img
 rm -rf "${BUILD_DIR}/genimage.tmp"                                                        || exit 1
 genimage --rootpath="${TARGET_DIR}" \
     --inputpath="${BINARIES_DIR}" \

configs/shredos_i686_lite_defconfig

@@ -6,6 +6,7 @@ BR2_TARGET_GENERIC_HOSTNAME="shredos"
 BR2_TARGET_GENERIC_ISSUE="Welcome to ShredOS https://github.com/PartialVolume/shredos.i686"
 BR2_INIT_SYSV=y
 BR2_ROOTFS_MERGED_USR=y
+BR2_SYSTEM_BIN_SH_BASH=y
 BR2_SYSTEM_DEFAULT_PATH="/bin:/sbin:/usr/bin:/usr/sbin"
 # BR2_ENABLE_LOCALE_PURGE is not set
 BR2_ROOTFS_OVERLAY="board/shredos/fsoverlay"