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Oleksandr ShyshatskyiandClaude Opus 5
ebc3d60c58
A printer flashed back to stock came up with the FlashForge screen and no Klipper behind it, and stayed that way however many times the stock package was flashed. The .cfg files were the obvious suspect and are not the fault: stock's run.sh does `cp $WORK_DIR/klipper/config/* /usr/data/config/ -rf`, and the printer's busybox unlinks a dangling symlink rather than writing through it, so printer.base.cfg and the seven beside it come back on every stock flash. The ff-*.cfg links left behind resolve to nothing and are included by nothing. Even the SAVE_CONFIG block our Klipper wrote into printer.cfg is harmless -- configfile.py marks every autosave section valid through access_tracking, so `[ff_tool 0]` there is not a config error on a stock klippy. All three were put to the printer's own binaries in the replica. What survives is /usr/prog/klipper/klipperDaemon. Every release links it at the mod, whose `start` does nothing on purpose -- klippy is an s6-rc longrun and a second unsupervised one would fight it for /dev/ttyS4 -- and the stock package has no klipperDaemon to copy over it: not in the software component, not in its md5sum.list, no line in run.sh. Stock's start.sh ends in `klipperDaemon start`, so the UI starts and klippy never does. installer/recovery.sh is the repair, packed by bin/pack-recovery.sh into a .tgz that carries no mod at all: FlashForge's own klipperDaemon, taken off a factory /usr/prog and gated on its md5, and their Klipper configs out of the stock package the build reads. It sweeps FlashForge's config directory by shape rather than by a list of names -- a symlink into $MODDIR there can only be ours -- refuses to run while the mod is still the firmware, and never touches printer.cfg, which no package has a copy of to put back. Output goes to work/recovery/: bin/pack.sh wipes work/out, and the replica lane installs the newest .tgz there as the mod under test. qa/replica/test_recovery.py holds the whole story against a real machine: the link the mod leaves, the busybox cp, the refusal, `klipperDaemon start` leaving no pid file, then the same command forking a real klippy once the file is back. Publishing lives in Klipper4FlashForge/stock-recovery, which checks this repo out and releases there, so a repair for owners of old releases is not buried among firmware releases they must not flash to get it. Two things found on the way, both in the harness rather than the mod: seed-prog.sh appended USER-CONFIG-MUST-SURVIVE as a plain comment after the SAVE_CONFIG header, and Klipper drops the entire autosave block on the first line there that does not start with '#*#'. Every replica ran with klippy seeing none of the machine's saved PID, shaper, mesh or probe values, and failing on an unrelated-looking missing option. It is written inside the block now, an older image's copy is repaired in place, and test_install.py asserts the invariant. installed_image() keyed its cache on the package md5 alone, so a rebuilt PRINTER_IMAGE silently handed back a bake from the old base -- which made the fix above read as ineffective twice before the cache was the suspect. The tag mixes in the base image id now, and build-printer-image.sh takes IMAGE_TAG so a rebuilt image can be published without moving a tag ci.yml pins. Co-Authored-By: Claude Opus 5 (1M context) <noreply@anthropic.com> Claude-Session: https://claude.ai/code/session_015hdzEqXuFcY4xXALGPbBFV