From 21c8870c0d369f025f8f9fc2fb0e86424307bdc1 Mon Sep 17 00:00:00 2001
From: Andreas Wrede <aew.git@wrede.ca>
Date: Tue, 4 Aug 2026 20:28:51 -0400
Subject: [PATCH] =?UTF-8?q?failover:=20add=20sync-sd-backup.sh=20=E2=80=94?=
 =?UTF-8?q?=20script=20the=20post-push=20SD=20fallback=20refresh?=
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The SD card (mmcblk0p2) is refreshed as a live boot-fallback clone of
NVMe root after pushes, but that rsync was being hand-typed each time
and its exclude list didn't cover /etc/fstab. That let it clobber the
SD's own fstab with the NVMe's PARTUUIDs, breaking SD-only boot (only
mounts correctly if the NVMe happens to also be present). Also excludes
/etc/machine-id and /var/log so the clone doesn't inherit the NVMe's
identity/journal history.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
---
 failover/sync-sd-backup.sh | 48 ++++++++++++++++++++++++++++++++++++++
 1 file changed, 48 insertions(+)
 create mode 100755 failover/sync-sd-backup.sh

diff --git a/failover/sync-sd-backup.sh b/failover/sync-sd-backup.sh
new file mode 100755
index 0000000..86c4ac1
--- /dev/null
+++ b/failover/sync-sd-backup.sh
@@ -0,0 +1,48 @@
+#!/usr/bin/env bash
+# Refresh the SD card (mmcblk0p2) as a live boot-fallback clone of the
+# running root filesystem. Run manually after a push:
+#   sudo ./failover/sync-sd-backup.sh
+#
+# EEPROM BOOT_ORDER falls back to the SD card if the primary boot disk
+# (NVMe) doesn't come up. /etc/fstab, /etc/machine-id, and /var/log are
+# excluded from the sync so the clone keeps its own partition identity
+# (PARTUUIDs differ per disk) and boot/journal history instead of
+# inheriting the source disk's — see failover/README or repo memory
+# "sd-fallback-fstab-clobber" for what breaks if those leak across.
+set -euo pipefail
+
+[ "$(id -u)" -eq 0 ] || { echo "Run as root (sudo)." >&2; exit 1; }
+
+SD_ROOT_PART=/dev/mmcblk0p2
+MOUNT_POINT=/mnt/sd-backup-root
+
+root_src=$(findmnt -no SOURCE /)
+if [ "$root_src" = "$SD_ROOT_PART" ]; then
+    echo "Currently booted from $SD_ROOT_PART — refusing to sync SD onto itself." >&2
+    exit 1
+fi
+
+mkdir -p "$MOUNT_POINT"
+mounted_here=0
+if ! mountpoint -q "$MOUNT_POINT"; then
+    mount "$SD_ROOT_PART" "$MOUNT_POINT"
+    mounted_here=1
+else
+    mount -o remount,rw "$MOUNT_POINT"
+fi
+
+cleanup() {
+    if [ "$mounted_here" -eq 1 ]; then
+        umount "$MOUNT_POINT"
+    fi
+}
+trap cleanup EXIT
+
+rsync -aHAX --numeric-ids --delete \
+    --exclude=/proc/* --exclude=/sys/* --exclude=/dev/* --exclude=/run/* \
+    --exclude=/tmp/* --exclude=/mnt/* --exclude=/media/* --exclude=/lost+found \
+    --exclude=/boot/firmware/* --exclude=/swapfile \
+    --exclude=/etc/fstab --exclude=/etc/machine-id --exclude=/var/log/* \
+    --stats / "$MOUNT_POINT/"
+
+echo "SD backup ($SD_ROOT_PART) synced from $root_src."