packer build fails due to BGinfo.exe being too big for a 1.44MB floppy

[dusek]

Bginfo.exe (downloaded today from the site linked in README using the Download BgInfo link) is 2.9MB, twice more than 1.44MB floppy max size:

$ ls -lh floppy/bginfo/Bginfo.exe 
-rwxr-xr-x@ 1 user  staff   2.9M Jan 17  2018 floppy/bginfo/Bginfo.exe

I will try a workaround by commenting out anything relating to setting background and do a build then, but thought you must have run into the issue yourself and that I should report it.

Full output of running packer build (some paths redacted for privacy):

$ packer build -only=virtualbox-iso -force -on-error=ask template-output/MSEdge-Win10.json                                                                                              
virtualbox-iso output will be in this color.

==> virtualbox-iso: Downloading or copying Guest additions
    virtualbox-iso: Downloading or copying: file:///path/to/VirtualBox.app/Contents/MacOS/VBoxGuestAdditions.iso                                                                                
==> virtualbox-iso: Downloading or copying ISO
    virtualbox-iso: Downloading or copying: file:///path/to/dev.microsoftedge.com-vms/scripts/iso/15063.0.170317-1834.RS2_RELEASE_CLIENTENTERPRISEEVAL_OEMRET_X64FRE_EN-US.iso
==> virtualbox-iso: Deleting previous output directory...
==> virtualbox-iso: Creating floppy disk...
    virtualbox-iso: Copying files flatly from floppy_files
    virtualbox-iso: Copying file: floppy/common/setautologon.ps1
    virtualbox-iso: Copying file: floppy/build.cfg
    virtualbox-iso: Copying file: floppy/openssh/openssh.ps1
    virtualbox-iso: Copying file: floppy/updates/win-updates.ps1
    virtualbox-iso: Copying file: floppy/common/post-win-updates.ps1
    virtualbox-iso: Copying file: floppy/common/finish-actions.ps1
    virtualbox-iso: Copying file: floppy/updates/microsoft-updates.bat
    virtualbox-iso: Copying file: floppy/common/preprovisioner.ps1
    virtualbox-iso: Copying file: floppy/bginfo/Bginfo.exe
==> virtualbox-iso: Error adding file from floppy_files : floppy/bginfo/Bginfo.exe : FAT FULL
==> virtualbox-iso: Step "StepCreateFloppy" failed
==> virtualbox-iso: [c] Clean up and exit, [a] abort without cleanup, or [r] retry step (build may fail even if retry succeeds)? c
==> virtualbox-iso: Deleting output directory...
Build 'virtualbox-iso' errored: Error adding file from floppy_files : floppy/bginfo/Bginfo.exe : FAT FULL

==> Some builds didn't complete successfully and had errors:
--> virtualbox-iso: Error adding file from floppy_files : floppy/bginfo/Bginfo.exe : FAT FULL

==> Builds finished but no artifacts were created.

Configuration:

• packer: 1.2.5
• Build host: macOS 10.3.6

For the record, the full MSEdge-Win10.json (which I merged from template-parts by hand (and adding one line to the vagrant post-processor to test a fix for #21) to avoid building packermerge since I am on a Mac):

{
  "variables": {
    "iso_url": "iso/15063.0.170317-1834.RS2_RELEASE_CLIENTENTERPRISEEVAL_OEMRET_X64FRE_EN-US.iso",
    "iso_checksum": "cf812813211add8fe7c53b07b7caff8c",
    "iso_checksum_type": "md5",
    "version": "0.1.0",
    "shutdown_command": "cscript c:/windows/system32/slmgr.vbs /rearm & shutdown /s /f /d p:4:1",
    "ssh_user" : "IEUser",
    "ssh_pwd" : "Passw0rd!",    
    "update": "true"
  },
  "builders": [
    {
      "type": "hyperv-iso",
      "vm_name": "MSEdge - Win10",
      "iso_url": "{{ user `iso_url` }}",
      "iso_checksum": "{{ user `iso_checksum` }}",
      "iso_checksum_type": "{{ user `iso_checksum_type` }}",
      "ssh_username": "{{ user `ssh_user` }}",
      "ssh_password": "{{ user `ssh_pwd` }}",
      "ssh_timeout": "16h",
      "ram_size": 2048,
      "disk_size": 40960,
      "switch_name": "",
      "shutdown_command": "{{ user `shutdown_command`}}",
      "output_directory" : "..\\vms\\output\\MSEdge-Win10-HyperV",
      "floppy_files": [
        "floppy/common/setautologon.ps1",
        "floppy/build.cfg",
        "floppy/openssh/openssh.ps1",
        "floppy/updates/win-updates.ps1",
        "floppy/common/post-win-updates.ps1",
        "floppy/common/finish-actions.ps1",
        "floppy/updates/microsoft-updates.bat",
        "floppy/common/preprovisioner.ps1",
        "floppy/bginfo/Bginfo.exe",
        "floppy/bginfo/install.vbs",
        "floppy/bginfo/background.jpg",
        "floppy/homepage/browser-homepage.ps1",
        "floppy/winrm/start-winrm.ps1",
        "floppy/winrm/config-winrm.cmd",
        "floppy/common/setautologon.ps1",
        "answer_files/10/autounattend.xml",
        "floppy/common/preprovisioner.cmd",
        "floppy/bginfo/win10/bgconfig.bgi",
        "floppy/eula/win10/eula.txt"
      ]
    },
    {
      "type": "virtualbox-iso",
      "vm_name": "MSEdge - Win10",
      "communicator": "ssh",
      "iso_url": "{{ user `iso_url` }}",
      "iso_checksum": "{{ user `iso_checksum` }}",
      "iso_checksum_type": "{{ user `iso_checksum_type` }}",
      "ssh_wait_timeout": "16h",
      "ssh_username": "{{ user `ssh_user` }}",
      "ssh_password": "{{ user `ssh_pwd` }}",
      "guest_os_type": "Windows10_64",
      "format" : "ova",
      "guest_additions_mode" : "attach",
      "output_directory" : "..\\vms\\output\\MSEdge-Win10-VirtualBox",
      "headless": "{{ user `headless` }}",
      "disk_size": 40960,
      "vboxmanage": [
        [
          "modifyvm",
          "{{.Name}}",
          "--memory",
          "4096"
        ]
      ],
      "shutdown_command": "{{ user `shutdown_command`}}",
      "floppy_files": [
        "floppy/common/setautologon.ps1",
        "floppy/build.cfg",
        "floppy/openssh/openssh.ps1",
        "floppy/updates/win-updates.ps1",
        "floppy/common/post-win-updates.ps1",
        "floppy/common/finish-actions.ps1",
        "floppy/updates/microsoft-updates.bat",
        "floppy/common/preprovisioner.ps1",
        "floppy/bginfo/install.vbs",
        "floppy/bginfo/background.jpg",
        "floppy/homepage/browser-homepage.ps1",
        "floppy/winrm/start-winrm.ps1",
        "floppy/winrm/config-winrm.cmd",
        "floppy/common/setautologon.ps1",
        "answer_files/10/autounattend.xml",
        "floppy/common/preprovisioner.cmd",
        "floppy/bginfo/win10/bgconfig.bgi",
        "floppy/eula/win10/eula.txt"        
      ]
    },
    {
      "type": "vmware-iso",
      "vm_name": "MSEdge - Win10",
      "iso_url": "{{ user `iso_url` }}",
      "iso_checksum": "{{ user `iso_checksum` }}",
      "iso_checksum_type": "{{ user `iso_checksum_type` }}",
      "headless": true,
      "ssh_username": "{{ user `ssh_user` }}",
      "ssh_password": "{{ user `ssh_pwd` }}",
      "ssh_wait_timeout": "16h",
      "shutdown_command": "{{ user `shutdown_command`}}",
      "guest_os_type": "windows9-64",
      "boot_wait": "2m",
      "tools_upload_flavor": "windows",
      "output_directory" : "..\\vms\\output\\MSEdge-Win10-VMware-vmx",
      "disk_size": 40960,
      "vnc_port_min": 5900,
      "vnc_port_max": 5980,
       "vmx_data": {
        "RemoteDisplay.vnc.enabled": "false",
        "RemoteDisplay.vnc.port": "5900",
        "memsize": "4096",
        "numvcpus": "2",
        "scsi0.virtualDev": "lsisas1068",
        "virtualHW.version": "12"
       },
      "floppy_files": [
        "floppy/common/setautologon.ps1",
        "floppy/build.cfg",
        "floppy/openssh/openssh.ps1",
        "floppy/updates/win-updates.ps1",
        "floppy/common/post-win-updates.ps1",
        "floppy/common/finish-actions.ps1",
        "floppy/updates/microsoft-updates.bat",
        "floppy/common/preprovisioner.ps1",
        "floppy/bginfo/Bginfo.exe",
        "floppy/bginfo/install.vbs",
        "floppy/bginfo/background.jpg",
        "floppy/homepage/browser-homepage.ps1",
        "floppy/winrm/start-winrm.ps1",
        "floppy/winrm/config-winrm.cmd",
        "floppy/common/setautologon.ps1",
        "answer_files/10/autounattend.xml",
        "floppy/common/preprovisioner.cmd",
        "floppy/bginfo/win10/bgconfig.bgi",
        "floppy/eula/win10/eula.txt"      
      ]
    },
    {
      "type": "parallels-iso",
      "vm_name": "MSEdge - Win10",
      "communicator": "ssh",
      "iso_url": "{{ user `iso_url` }}",
      "iso_checksum": "{{ user `iso_checksum` }}",
      "iso_checksum_type": "{{ user `iso_checksum_type` }}",
      "parallels_tools_flavor": "win",
      "parallels_tools_mode": "upload",
      "ssh_username": "{{ user `ssh_user` }}",
      "ssh_password": "{{ user `ssh_pwd` }}",
      "ssh_wait_timeout": "16h",
      "shutdown_command": "{{ user `shutdown_command`}}",
      "output_directory" : "MSEdge-Win10-Parallels",
      "guest_os_type": "win-10",
      "prlctl": [
        ["set", "{{.Name}}", "--memsize", "2048"],
        ["set", "{{.Name}}", "--cpus", "2"]
      ],
      "floppy_files": [
        "floppy/common/setautologon.ps1",
        "floppy/build.cfg",
        "floppy/openssh/openssh.ps1",
        "floppy/updates/win-updates.ps1",
        "floppy/common/post-win-updates.ps1",
        "floppy/common/finish-actions.ps1",
        "floppy/updates/microsoft-updates.bat",
        "floppy/common/preprovisioner.ps1",
        "floppy/bginfo/Bginfo.exe",
        "floppy/bginfo/install.vbs",
        "floppy/bginfo/background.jpg",
        "floppy/homepage/browser-homepage.ps1",
        "floppy/winrm/start-winrm.ps1",
        "floppy/winrm/config-winrm.cmd",
        "floppy/common/setautologon.ps1",
        "answer_files/10/autounattend.xml",
        "floppy/common/preprovisioner.cmd",
        "floppy/bginfo/win10/bgconfig.bgi",
        "floppy/eula/win10/eula.txt"
      ]
    }
  ],
  "provisioners": [
    {
      "type": "shell",
      "remote_path": "/tmp/script.bat",
      "execute_command": "{{.Vars}} cmd /c C:/Windows/Temp/script.bat",
      "scripts": [
        "./provisioners/vm-guest-tools.bat",
        "./provisioners/compact.bat",
        "./provisioners/restore-uac.bat",
        "./provisioners/disable-autologon.bat"        
      ]
    }
  ],
  "post-processors": [
    {
      "type": "vagrant",
      "compression_level": 6,
      "keep_input_artifact": true,
      "vagrantfile_template": "template-parts/Vagrantfile",
      "output": "..\\vms\\output\\Vagrant\\edgems.box",
      "only": ["virtualbox-iso"]
    }
  ]  
}

[molant]

@dusek I switched to using a cdrom and EFI for windows 10. I haven't uploaded the code yet because there are some parts that arent fully automated. Another option is to dig an older version of that file that's smaller.

[dusek]

@molant Thanks for the tips. In the end, I managed to work around this by removing BGinfo.exe from the floppy and commenting out copying and execution of BGinfo.exe in install.vbs.

[dragon788]

Technically there were 2.88MB floppies in the past and as a virtual floppy the size shouldn't matter unless it is hardcoded to a certain size somewhere.