Merge pull request #3027 from flatcar/ader1990/increase_boot_partition

Increase partition sizes

build_library/disk_layout.json

@@ -13,7 +13,7 @@
         "label":"EFI-SYSTEM",
         "fs_label":"EFI-SYSTEM",
         "type":"efi",
-        "blocks":"262144",
+        "blocks":"2097152",
         "fs_type":"vfat",
         "mount":"/boot",
         "features": []
@@ -27,7 +27,8 @@
         "label":"USR-A",
         "uuid":"7130c94a-213a-4e5a-8e26-6cce9662f132",
         "type":"flatcar-rootfs",
-        "blocks":"2097152",
+        "blocks":"4194304",
+        "extract_blocks":"2097152",
         "fs_blocks":"260094",
         "fs_type":"btrfs",
         "fs_compression":"zstd",
@@ -38,7 +39,8 @@
         "label":"USR-B",
         "uuid":"e03dd35c-7c2d-4a47-b3fe-27f15780a57c",
         "type":"flatcar-rootfs",
-        "blocks":"2097152",
+        "blocks":"4194304",
+        "extract_blocks":"2097152",
         "fs_blocks":"262144"
       },
       "5":{
@@ -51,7 +53,7 @@
         "label":"OEM",
         "fs_label":"OEM",
         "type":"data",
-        "blocks":"262144",
+        "blocks":"2097152",
         "fs_type":"btrfs",
         "fs_compression":"zlib",
         "mount":"/oem"
@@ -70,7 +72,7 @@
         "label":"ROOT",
         "fs_label":"ROOT",
         "type":"flatcar-resize",
-        "blocks":"4427776",
+        "blocks":"3653632",
         "fs_type":"ext4",
         "mount":"/"
       }

build_library/disk_util

@@ -40,10 +40,10 @@ def LoadPartitionConfig(options):
       '_comment', 'type', 'num', 'label', 'blocks', 'block_size', 'fs_blocks',
       'fs_block_size', 'fs_type', 'features', 'uuid', 'part_alignment', 'mount',
       'binds', 'fs_subvolume', 'fs_bytes_per_inode', 'fs_inode_size', 'fs_label',
-      'fs_compression'))
+      'fs_compression', 'extract_blocks'))
   integer_layout_keys = set((
       'blocks', 'block_size', 'fs_blocks', 'fs_block_size', 'part_alignment',
-      'fs_bytes_per_inode', 'fs_inode_size'))
+      'fs_bytes_per_inode', 'fs_inode_size', 'extract_blocks'))
   required_layout_keys = set(('type', 'num', 'label', 'blocks'))
 
   filename = options.disk_layout_file
@@ -136,6 +136,13 @@ def LoadPartitionConfig(options):
       part.setdefault('fs_block_size', metadata['fs_block_size'])
       part.setdefault('fs_blocks', part['bytes'] // part['fs_block_size'])
       part['fs_bytes'] = part['fs_blocks'] * part['fs_block_size']
+      # The partition may specify extract_blocks to limit what content gets
+      # extracted. The use case is the /usr partition where we can grow the
+      # partition but can't directly grow the filesystem and the update
+      # payload until all (or most) nodes are running the partition layout
+      # with the grown /usr partition (which can take a few years).
+      if part.get('extract_blocks', None):
+        part['extract_bytes'] = part['extract_blocks'] * metadata['block_size']
 
       if part['fs_bytes'] > part['bytes']:
         raise InvalidLayout(
@@ -823,6 +830,7 @@ def Extract(options):
   if not part['image_compat']:
     raise InvalidLayout("Disk layout is incompatible with existing image")
 
+  extract_size = part.get('extract_bytes', part['image_bytes'])
   subprocess.check_call(['dd',
                          'bs=10MB',
                          'iflag=count_bytes,skip_bytes',
@@ -831,7 +839,7 @@ def Extract(options):
                          'if=%s' % options.disk_image,
                          'of=%s' % options.output,
                          'skip=%s' % part['image_first_byte'],
-                         'count=%s' % part['image_bytes']])
+                         'count=%s' % extract_size])
 
 
 def GetPartitionByNumber(partitions, num):

build_library/vm_image_util.sh

@@ -224,9 +224,11 @@ IMG_ami_vmdk_DISK_FORMAT=vmdk_stream
 IMG_ami_vmdk_OEM_USE=ami
 IMG_ami_vmdk_OEM_PACKAGE=common-oem-files
 IMG_ami_vmdk_SYSEXT=oem-ami
+IMG_ami_vmdk_DISK_LAYOUT=vm
 IMG_ami_OEM_USE=ami
 IMG_ami_OEM_PACKAGE=common-oem-files
 IMG_ami_OEM_SYSEXT=oem-ami
+IMG_ami_DISK_LAYOUT=vm
 
 ## openstack
 IMG_openstack_DISK_FORMAT=qcow2
@@ -342,6 +344,7 @@ IMG_kubevirt_OEM_SYSEXT=oem-kubevirt
 IMG_kubevirt_DISK_EXTENSION=qcow2
 
 ## akamai (Linode)
+IMG_akamai_DISK_LAYOUT=vm
 IMG_akamai_OEM_PACKAGE=common-oem-files
 IMG_akamai_OEM_USE=akamai
 IMG_akamai_OEM_SYSEXT=oem-akamai

changelog/changes/2025-10-09-partition-sizes.md

@@ -0,0 +1 @@
+- Increased all partition sizes: `/boot` to 1 GB, the two `/usr` partitions to 2 GB, `/oem` to 1 GB so that we can use more space in a few years when we can assume that most nodes run the new partition layout - existing nodes can still update for the next years ([scripts#3027](https://github.com/flatcar/scripts/pull/3027))