I/O error 'File too large' in --mrsync mode

[joaocandre]

bootiso: 4.2.0

Category: Behavior

Describe the bug

When attempting to create a bootable USB from a Windows 11 iso, I get:

bootiso: Copying files from image to USB device with 'rsync'   |rsync: [receiver] write failed on "/var/tmp/bootiso/mnt/usb-MUa/sources/install.esd": File too large (27)
rsync error: error in file IO (code 11) at receiver.c(380) [receiver=3.2.7]
rsync: [sender] write error: Broken pipe (32)

Expected behavior (for behavioral bugs only)

I'm calling bootiso in Mount-Rsync mode, but sources/install.esd (with a size 4.6 Gb) isn't being split.

Reproduction

Run bootiso --mrsync <iso> with a Windows 11 Pro x64 ISO (only have the one, not sure if it's ISO-specific):

sfdisk: win11pro.iso: does not contain a recognized partition table
bootiso: Found non-hybrid image; inspecting image for boot capabilities... 
bootiso: UEFI boot check validated. Your USB will work with UEFI boot. 
bootiso: Partition label automatically set to 'WIN11 PRO E'. You can explicitly set the label with -L, 
         --label. 
bootiso: The selected device '/dev/sdb' is connected through USB. 
bootiso: About to wipe the content of device '/dev/sdb'. 
         Are you sure you want to proceed? (y/n)> y
bootiso: Erasing contents of '/dev/sdb'... 
bootiso: Creating MBR partition table with 'sfdisk' v2.39... 
         Checking that no-one is using this disk right now ... OK 
         
         Disk /dev/sdb: 14.55 GiB, 15623258112 bytes, 30514176 sectors 
         Disk model: DataTraveler 111 
         Units: sectors of 1 * 512 = 512 bytes 
         Sector size (logical/physical): 512 bytes / 512 bytes 
         I/O size (minimum/optimal): 512 bytes / 512 bytes 
         
         >>> Script header accepted. 
         >>> Created a new DOS (MBR) disklabel with disk identifier 0x8b3e987a. 
         /dev/sdb1: Created a new partition 1 of type 'W95 FAT32 (LBA)' and of size 14.5 GiB. 
         Partition #1 contains a vfat signature. 
         The signature will be removed by a write command. 
         /dev/sdb2: Done. 
         
         New situation: 
         Disklabel type: dos 
         Disk identifier: 0x8b3e987a 
         
         Device Boot Start End Sectors Size Id Type 
         /dev/sdb1 2048 30514175 30512128 14.5G c W95 FAT32 (LBA) 
         
         Filesystem/RAID signature on partition 1 will be wiped. 
         
         The partition table has been altered. 
         Calling ioctl() to re-read partition table. 
         Syncing disks. 
bootiso: Creating vfat partition on '/dev/sdb1'... 
         mkfs.fat 4.2 (2021-01-31) 
         /dev/sdb1 has 64 heads and 32 sectors per track, 
         hidden sectors 0x0800; 
         logical sector size is 512, 
         using 0xf8 media descriptor, with 30512128 sectors; 
         drive number 0x80; 
         filesystem has 2 32-bit FATs and 16 sectors per cluster. 
         FAT size is 14896 sectors, and provides 1905144 clusters. 
         There are 32 reserved sectors. 
         Volume ID is 748acbbb, volume label WIN11 PRO E. 

bootiso: Created USB device mount point at '/var/tmp/bootiso/mnt/usb-MUa' 
bootiso: Copying files from image to USB device with 'rsync'   |rsync: [receiver] write failed on "/var/tmp/bootiso/mnt/usb-MUa/sources/install.esd": File too large (27)
rsync error: error in file IO (code 11) at receiver.c(380) [receiver=3.2.7]
rsync: [sender] write error: Broken pipe (32)

Exit status

64 ( I/O error: a read/write command has unexpectedly failed.)

Environment:

                   -`                    user@user-laptop 
                  .o+`                   ---------------- 
                 `ooo/                   OS: Arch Linux x86_64 
                `+oooo:                  Host: Latitude 7490 
               `+oooooo:                 Kernel: 6.4.2-arch1-1 
               -+oooooo+:                Uptime: 6 hours, 24 mins 
             `/:-:++oooo+:               Packages: 838 (pacman) 
            `/++++/+++++++:              Shell: bash 5.1.16 
           `/++++++++++++++:             Resolution: 1920x1080 
          `/+++ooooooooooooo/`           DE: GNOME 44.3 
         ./ooosssso++osssssso+`          WM: Mutter 
        .oossssso-````/ossssss+`         WM Theme: Adwaita 
       -osssssso.      :ssssssso.        Theme: Adwaita [GTK2/3] 
      :osssssss/        osssso+++.       Icons: Papirus [GTK2/3] 
     /ossssssss/        +ssssooo/-       Terminal: kgx 
   `/ossssso+/:-        -:/+osssso+-     CPU: Intel i7-8650U (8) @ 4.200GHz 
  `+sso+:-`                 `.-/+oso:    GPU: Intel UHD Graphics 620 
 `++:.                           `-/+/   Memory: 6377MiB / 15873MiB 
 .`                                 `/
                                                                 
                                                                 

rsync version 3.2.7 is installed.

Additional context (optional)

I've previously tried to create a bootable USB with WoeUSB and everything went fine until the first reboot after installation, with the error "Windows can't prepare the device to boot into the next phase of the installation" which I'm not sure is even remotely related, but which I suspect was down to how the USB was created.

Suggestion fix (optional)

The documentation mentions that in Mount-Rsync installation mode, if a Windows /sources/install.wim file is found, wimlib-imagex(1) will be used to circumvent FAT32 filesystem size limitations., however, from the error message it seems that isn't happening with /sources/install.esd. I wonder if only /sources/install.wim files are split (which I found none on this particular ISO), or if that extends to any file over 4 Gb.