[FS#484] Image Builder generates broken image for ASUS WL500W

[LEDE Bugs]

A new Flyspray task has been opened.  Details are below. 

User who did this - Mirko Parthey (mpa) 

Attached to Project - LEDE Project
Summary - Image Builder generates broken image for ASUS WL500W
Task Type - Bug Report
Category - Other
Status - Unconfirmed
Assigned To - 
Operating System - All
Severity - Low
Priority - Very Low
Reported Version - lede-17.01
Due in Version - Undecided
Due Date - Undecided
Details - ====Software Revision====
LEDE 17.01.0-rc2

====Device====
ASUS WL500W

====Issue description====
An image generated with the Image Builder can be booted only once after flashing it. On the second and further boot attempts, the device stays in the bootloader.

The OpenWrt 15.05.1 Image Builder is not affected. The official 17.01.0-rc2 image also works fine.

I wonder if the following Image Builder message hints at the problem:

WARNING: maxlen exceeds default maximum!  Beware of overwriting nvram!



The Image Builder result is actually smaller than the official image, 3608576 vs. 4001792 bytes.

====Steps to reproduce====

  * Use Debian Jessie amd64 or another suitable host system
  * Unpack lede-imagebuilder-17.01.0-rc2-brcm47xx-legacy.Linux-x86_64.tar.xz
  * Within the Image Builder directory: make image PROFILE=asus-wl-500w
  * Copy this resulting image to the device: bin/targets/brcm47xx/legacy/lede-17.01.0-rc2-r3131-42f3c1f-brcm47xx-legacy-asus-wl-500w-squashfs.trx
  * sysupgrade -n -v *.trx
  * Wait for automatic reboot, wait another 3 minutes
  * ssh root at 192.168.1.1
  * Check dmesg for "jffs2 [...] complete" message, or wait until it appears
  * reboot

The device is now stuck in the bootloader, power-cycling does not help.

I can do further tests if necessary.

Regards,
Mirko

More information can be found at the following URL:
https://bugs.lede-project.org/index.php?do=details&task_id=484