Fix offline mode

functions/private/Invoke-WinUtilISOUSB.ps1

@@ -103,13 +103,24 @@ function Invoke-WinUtilISOWriteUSB {
         try {
             SetProgress "Formatting USB drive..." 10
 
-            # Phase 1: Clean disk via diskpart
+            # Phase 1: Clean disk via diskpart (retry once if the drive is not yet ready)
             $dpFile1 = Join-Path $env:TEMP "winutil_diskpart_$(Get-Random).txt"
             "select disk $diskNum`nclean`nexit" | Set-Content -Path $dpFile1 -Encoding ASCII
             Log "Running diskpart clean on Disk $diskNum..."
-            diskpart /s $dpFile1 2>&1 | Where-Object { $_ -match '\S' } | ForEach-Object { Log "  diskpart: $_" }
+            $dpCleanOut = diskpart /s $dpFile1 2>&1
+            $dpCleanOut | Where-Object { $_ -match '\S' } | ForEach-Object { Log "  diskpart: $_" }
             Remove-Item $dpFile1 -Force -ErrorAction SilentlyContinue
 
+            if (($dpCleanOut -join ' ') -match 'device is not ready') {
+                Log "Disk $diskNum was not ready; waiting 5 seconds and retrying clean..."
+                Start-Sleep -Seconds 5
+                Update-Disk -Number $diskNum -ErrorAction SilentlyContinue
+                $dpFile1b = Join-Path $env:TEMP "winutil_diskpart_$(Get-Random).txt"
+                "select disk $diskNum`nclean`nexit" | Set-Content -Path $dpFile1b -Encoding ASCII
+                diskpart /s $dpFile1b 2>&1 | Where-Object { $_ -match '\S' } | ForEach-Object { Log "  diskpart: $_" }
+                Remove-Item $dpFile1b -Force -ErrorAction SilentlyContinue
+            }
+
             # Phase 2: Initialize as GPT
             Start-Sleep -Seconds 2
             Update-Disk -Number $diskNum -ErrorAction SilentlyContinue
@@ -122,7 +133,8 @@ function Invoke-WinUtilISOWriteUSB {
                 Log "Disk $diskNum converted to GPT (was $($diskObj.PartitionStyle))."
             }
 
-            # Phase 3: Create FAT32 partition via diskpart
+            # Phase 3: Create FAT32 partition via diskpart, then format with Format-Volume
+            # (diskpart's 'format' command can fail with "no volume selected" on fresh/never-formatted drives)
             $volLabel = "W11-" + (Get-Date).ToString('yyMMdd')
             $dpFile2  = Join-Path $env:TEMP "winutil_diskpart2_$(Get-Random).txt"
             $maxFat32PartitionMB = 32768
@@ -136,29 +148,38 @@ function Invoke-WinUtilISOWriteUSB {
             @(
                 "select disk $diskNum"
                 $createPartitionCommand
-                "select partition 1"
-                "format quick fs=fat32 label=`"$volLabel`""
                 "exit"
             ) | Set-Content -Path $dpFile2 -Encoding ASCII
             Log "Creating partitions on Disk $diskNum..."
             diskpart /s $dpFile2 2>&1 | Where-Object { $_ -match '\S' } | ForEach-Object { Log "  diskpart: $_" }
             Remove-Item $dpFile2 -Force -ErrorAction SilentlyContinue
 
-            SetProgress "Assigning drive letters..." 30
+            SetProgress "Formatting USB partition..." 25
             Start-Sleep -Seconds 3
             Update-Disk -Number $diskNum -ErrorAction SilentlyContinue
 
             $partitions = Get-Partition -DiskNumber $diskNum -ErrorAction Stop
-            Log "Partitions on Disk $diskNum after format: $($partitions.Count)"
+            Log "Partitions on Disk $diskNum after creation: $($partitions.Count)"
             foreach ($p in $partitions) {
                 Log "  Partition $($p.PartitionNumber)  Type=$($p.Type)  Letter=$($p.DriveLetter)  Size=$([math]::Round($p.Size/1MB))MB"
             }
 
             $winpePart = $partitions | Where-Object { $_.Type -eq "Basic" } | Select-Object -Last 1
             if (-not $winpePart) {
-                throw "Could not find the WINPE (Basic) partition on Disk $diskNum after format."
+                throw "Could not find the Basic partition on Disk $diskNum after creation."
             }
 
+            # Format using Format-Volume (reliable on fresh drives; diskpart format fails
+            # with 'no volume selected' when the partition has never been formatted before)
+            Log "Formatting Partition $($winpePart.PartitionNumber) as FAT32 (label: $volLabel)..."
+            Get-Partition -DiskNumber $diskNum -PartitionNumber $winpePart.PartitionNumber |
+                Format-Volume -FileSystem FAT32 -NewFileSystemLabel $volLabel -Force -Confirm:$false | Out-Null
+            Log "Partition $($winpePart.PartitionNumber) formatted as FAT32."
+
+            SetProgress "Assigning drive letters..." 30
+            Start-Sleep -Seconds 2
+            Update-Disk -Number $diskNum -ErrorAction SilentlyContinue
+
             try { Remove-PartitionAccessPath -DiskNumber $diskNum -PartitionNumber $winpePart.PartitionNumber -AccessPath "$($winpePart.DriveLetter):" -ErrorAction SilentlyContinue } catch {}
             $usbLetter = Get-FreeDriveLetter
             if (-not $usbLetter) { throw "No free drive letters (D-Z) available to assign to the USB data partition." }
@@ -167,6 +188,12 @@ function Invoke-WinUtilISOWriteUSB {
             Start-Sleep -Seconds 2
 
             $usbDrive = "${usbLetter}:"
+            $retries = 0
+            while (-not (Test-Path $usbDrive) -and $retries -lt 6) {
+                $retries++
+                Log "Waiting for $usbDrive to become accessible (attempt $retries/6)..."
+                Start-Sleep -Seconds 2
+            }
             if (-not (Test-Path $usbDrive)) { throw "Drive $usbDrive is not accessible after letter assignment." }
             Log "USB data partition: $usbDrive"
 

scripts/main.ps1

@@ -15,12 +15,14 @@ $maxthreads = [int]$env:NUMBER_OF_PROCESSORS
 $hashVars = New-object System.Management.Automation.Runspaces.SessionStateVariableEntry -ArgumentList 'sync',$sync,$Null
 $debugVar = New-object System.Management.Automation.Runspaces.SessionStateVariableEntry -ArgumentList 'DebugPreference',$DebugPreference,$Null
 $uiVar = New-object System.Management.Automation.Runspaces.SessionStateVariableEntry -ArgumentList 'PARAM_NOUI',$PARAM_NOUI,$Null
+$offlineVar = New-object System.Management.Automation.Runspaces.SessionStateVariableEntry -ArgumentList 'PARAM_OFFLINE',$PARAM_OFFLINE,$Null
 $InitialSessionState = [System.Management.Automation.Runspaces.InitialSessionState]::CreateDefault()
 
 # Add the variable to the session state
 $InitialSessionState.Variables.Add($hashVars)
 $InitialSessionState.Variables.Add($debugVar)
 $InitialSessionState.Variables.Add($uiVar)
+$InitialSessionState.Variables.Add($offlineVar)
 
 # Get every private function and add them to the session state
 $functions = Get-ChildItem function:\ | Where-Object { $_.Name -imatch 'winutil|WPF' }
@@ -350,11 +352,10 @@ $sync["Form"].Add_ContentRendered({
         Write-Debug "Unable to retrieve information about the primary monitor."
     }
 
-    # Check internet connectivity and disable install tab if offline
-    #$isOnline = Test-WinUtilInternetConnection
-    $isOnline = $true # Temporarily force online mode until we can resolve false negatives
+    if ($PARAM_OFFLINE) {
+        # Show offline banner
+        $sync.WPFOfflineBanner.Visibility = [System.Windows.Visibility]::Visible
 
-    if (-not $isOnline) {
         # Disable the install tab
         $sync.WPFTab1BT.IsEnabled = $false
         $sync.WPFTab1BT.Opacity = 0.5

scripts/start.ps1

@@ -9,7 +9,8 @@
 param (
     [string]$Config,
     [switch]$Run,
-    [switch]$Noui
+    [switch]$Noui,
+    [switch]$Offline
 )
 
 if ($Config) {
@@ -27,6 +28,11 @@ if ($Noui) {
     $PARAM_NOUI = $true
 }
 
+$PARAM_OFFLINE = $false
+if ($Offline) {
+    $PARAM_OFFLINE = $true
+}
+
 
 if (!([Security.Principal.WindowsPrincipal][Security.Principal.WindowsIdentity]::GetCurrent()).IsInRole([Security.Principal.WindowsBuiltInRole]::Administrator)) {
     Write-Output "Winutil needs to be run as Administrator. Attempting to relaunch."

xaml/inputXML.xaml

@@ -943,13 +943,19 @@
     </Window.Resources>
     <Grid Background="{DynamicResource MainBackgroundColor}" ShowGridLines="False" Name="WPFMainGrid" Width="Auto" Height="Auto" HorizontalAlignment="Stretch">
         <Grid.RowDefinitions>
+            <RowDefinition Height="Auto"/>
             <RowDefinition Height="Auto"/>
             <RowDefinition Height="*"/>
         </Grid.RowDefinitions>
         <Grid.ColumnDefinitions>
             <ColumnDefinition Width="*"/>
         </Grid.ColumnDefinitions>
-        <Grid Grid.Row="0" Background="{DynamicResource MainBackgroundColor}">
+        <!-- Offline banner -->
+        <Border Name="WPFOfflineBanner" Grid.Row="0" Background="#8B0000" Visibility="Collapsed" Padding="6,4">
+            <TextBlock Text="&#x26A0; Offline Mode - No Internet Connection" Foreground="White" FontWeight="Bold"
+                HorizontalAlignment="Center" FontSize="13" Background="Transparent"/>
+        </Border>
+        <Grid Grid.Row="1" Background="{DynamicResource MainBackgroundColor}">
             <Grid.ColumnDefinitions>
                 <ColumnDefinition Width="Auto"/> <!-- Navigation buttons -->
                 <ColumnDefinition Width="*"/> <!-- Search bar and buttons -->
@@ -1192,7 +1198,7 @@
             </Grid>
         </Grid>
 
-        <TabControl Name="WPFTabNav" Background="Transparent" Width="Auto" Height="Auto" BorderBrush="Transparent" BorderThickness="0" Grid.Row="1" Grid.Column="0" Padding="-1">
+        <TabControl Name="WPFTabNav" Background="Transparent" Width="Auto" Height="Auto" BorderBrush="Transparent" BorderThickness="0" Grid.Row="2" Grid.Column="0" Padding="-1">
             <TabItem Header="Install" Visibility="Collapsed" Name="WPFTab1">
                 <Grid Background="Transparent" >