[opensuse] openSUSE 11.1 - of grub,md/lvm root, and related headaches



I have had a system running fine since oss 10.1 (upgraded from there on to the current nightmare that is 11.1).

Here is the system disk layout:

Two 300 GB SATA hard drives - sda and sdba
sda1 and sdb1 are 130 MG, them mirrored using md raid into /dev/md0. /dev/md0 has ext3 mounted as /boot.
sda2 and sdb2 are 1 GB, then mirrored using md raid into /dev/md1. /dev/md1 is swap.
sda3 and sdb3 are 274 GB, then mirrored using md raid into /dev/md2. /dev/md2 has lvm on it, with / being /dev/system/system.
Grub installed in mbr of sda.

This system has been running great. I upgraded in-place from 11.0 to 11.1, and everything was still fine.
Then I built a custom kernel (as I have done with all other versions - the only thing I change is set the processor type). During the custom kernel install phase, make modules_install worked fine, but I noticed some weird device-mapper "no such file or device" error message during make install. I did not think much of it (probably a BIG mistake). Verified new vmlinuz and initrd were in place and /boot/grub/menu.lst looked kosher. Rebooted the system, and it went to pot.

On reboot, the machine displays the word "GRUB" and just hangs there. Only thing I can do at that point is to reboot.
Booted from 11.1 install disk, went into "repair installed system", no joy - this "repair installed system" did not see any md devices, nor any lvs.
Booted from 11.1 install disk, went into rescue mode. I was able to mount all my partitions successfully, I was able to chroot to my original root, go into yast etc. I reinstalled grub to mbr of sda, no errors. I googled and found a fix for the device mapper errors during mkinitrd (it had to do with a bug in Tools.pm), re-made and installed the kernel etc. Rebooted the system, same behavior, it just hangs after printing GRUB.

At this point, I have done about everything I can think of to revive it to no joy. Finally I made a grub boot CD, and have it use the kernel and initrd in place on the hard drives, and the system comes up fine. I am completely lost as to why grub will not boot from the HDD. I have tried reinstalled Grub to theMBR, as well as to the boot sector of the active parition (/dev/sda1) to no avail.

During googling for solutions, I read bits and pieces about how oss 11.1 uses a different mechanism for mkinitrd, something about relying on device mapper etc. While I do not fully understand what the changes are, I hope someone on the list does and can readily see what could be ailing my system and suggest a way out. In the meantime, the system continues to run after booting from a CD.

Thanks in advance for any help,



--
--Moby

They that can give up essential liberty to obtain a little temporary safety deserve neither liberty nor safety. -- Benjamin Franklin


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