How to create bootable USB for ESXi 4.1 update1 with unetbootin on ubuntu 11.04

[ software info ]

ubuntu 11.04 server 64bit : 2.6.38-10-server
syslinux 4.02
unetbootin : 471-2ubuntu1
ESXi 4.1 update1 : VMware-VMvisor-Installer-4.1.0.update1-348481.x86_64.iso

[ logs ]

Step1

prepare USB stick ( I prepared 4GB USB stick. BUFFALO: model name YUF-4G-WH )
create a partition and format it by VFAT.

USB stick device name ( /dev/sdg )
create a partition ( /dev/sdg1 )

root@hat1:~# LANG=C fdisk  /dev/sdg WARNING: DOS-compatible mode is deprecated. It's strongly recommended to        switch off the mode (command 'c') and change display units to        sectors (command 'u'). Command (m for help): p   <- no partitions Disk /dev/sdg: 4007 MB, 4007657472 bytes 124 heads, 62 sectors/track, 1018 cylinders Units = cylinders of 7688 * 512 = 3936256 bytes Sector size (logical/physical): 512 bytes / 512 bytes I/O size (minimum/optimal): 512 bytes / 512 bytes Disk identifier: 0x4911f7a1  Device Boot      Start         End      Blocks   Id  System Command (m for help): n   <- create a primary partition. # is 1 Command action  e   extended  p   primary partition (1-4) p Partition number (1-4): 1 <- partition 1 First cylinder (1-1018, default 1): 1  <- size Last cylinder, +cylinders or +size{K,M,G} (1-1018, default 1018): +450M Command (m for help): a  <- toggle bootable flag Partition number (1-4): 1 <- partition number 1 Command (m for help): t  <- change partition type as W95 FAT32 Selected partition 1  <- partition number 1 Hex code (type L to list codes): b  <- W95 FAT32 Changed system type of partition 1 to b (W95 FAT32) Command (m for help): w  <- save configuration The partition table has been altered! Calling ioctl() to re-read partition table. WARNING: If you have created or modified any DOS 6.x partitions, please see the fdisk manual page for additional information. Syncing disks.

root@hat1:~# LANG=C fdisk -l /dev/sdg Disk /dev/sdg: 4007 MB, 4007657472 bytes 124 heads, 62 sectors/track, 1018 cylinders Units = cylinders of 7688 * 512 = 3936256 bytes Sector size (logical/physical): 512 bytes / 512 bytes I/O size (minimum/optimal): 512 bytes / 512 bytes Disk identifier: 0x4911f7a1  Device Boot      Start         End      Blocks   Id  System /dev/sdg1   *           1         121      465093    b  W95 FAT32

Step2

format it

root@hat1:~# mkfs.vfat -n BOOT -F 32 /dev/sdg1 mkfs.vfat 3.0.9 (31 Jan 2010)

Step3

install unetbootin to  create a bootable USB.

root@hat1:~# apt-cache search unetbootin unetbootin - installer of Linux/BSD distributions to a partition or USB drive root@hat1:~# apt-get install unetbootin root@hat1:~# dpkg -l unetbootin | tail -1 ii  unetbootin                            471-2ubuntu1                                 installer of Linux/BSD distributions to a partition or USB drive

connect USB stick and mount a partition you created.
then start unetbootin.

# mount /dev/sdg1 /media/USB/ # unetbootin

seletct ISO image and press OK.

creating

overwrite menu.c32 ( click yes )

done. click exit.

change directory

root@hat1:~# cd /media/USB/ root@hat1:/media/USB# ls README.txt  cisco_n1k     isolinux.bin  open_source_licenses.txt  ubnpathl.txt a.z         ienviron.vgz  isolinux.cfg  sys.vgz                   vmkboot.gz boot.cat    imagedd.bz2   ldlinux.sys   syslinux.cfg              vmkernel.gz cim.vgz     imagedd.md5   mboot.c32     tboot.gz cimstg.tgz  install.vgz   menu.c32      ubnfilel.txt

Step4

modify syslinux.cfg. add “ks=usb:/ks.cfg”

root@hat1:/media/USB# cat syslinux.cfg default menu.c32 menu title VMware VMvisor Boot Menu timeout 80 label ESXi Installer menu label ^ESXi Installer kernel mboot.c32 append vmkboot.gz ks=usb:/ks.cfg --- vmkernel.gz --- sys.vgz --- cim.vgz --- ienviron.vgz --- install.vgz label ^Boot from local disk menu label ^Boot from local disk localboot 0x80

Step5

make ks.cfg file.

root@hat1:/media/USB# cat ks.cfg vmaccepteula rootpw welcome autopart --firstdisk --overwritevmfs install usb network --bootproto=static --ip=192.168.11.200 --gateway=192.168.11.1 --hostname=sumavihv --device=vmnic0 --nameserver=192.168.11.1 --netmask=255.255.255.0

Step6

copy /usr/lib/syslinux/mboot.c32 and /usr/lib/syslinux/menu.c32 to the USB stick’s partition.

root@hat1:/media/USB# cp /usr/lib/syslinux/mboot.c32 . root@hat1:/media/USB# cp /usr/lib/syslinux/menu.c32 .

unmont a partition.

root@hat1:~# umount /dev/sdg1

that’s it !

I could install ESXi 4.1 U1 using this USB stick on HP ML110 G6 :)

procedures are:

connect USB stick and boot from USB stick
install ESXi in DL110’s HDD
after finishing the installation , press reboot
disconnect USB stick