Issue with tegraflash after changing rootfs partition sizes

[joeced]

Recently we had to increase the rootfs size via ROOTFSPART_SIZE_DEFAULT from the default 2.5 GB to 6.5 GB. We are working with an Orin-NX16 with a 256GB external NVME attached. I tried it both in a devkit and our custom board.

It works, in the sense that the rootfs is increased. However, for some of the boards we are working on, we sometimes get the following error when tegraflashing with: sudo ./initrd-flash:

== Step 4: Writing partitions on external storage device at 2025-07-16T14:02:08+02:00 ==
Waiting for USB storage device nvme0n1 from 6ab465f9...[/dev/sda]
Creating partitions
  [01] name=A_kernel start=0 size=262144 sectors
  [02] name=A_kernel-dtb start=0 size=1536 sectors
  [03] name=B_kernel start=0 size=262144 sectors
  [04] name=B_kernel-dtb start=0 size=1536 sectors
  [05] name=esp start=0 size=131072 sectors
  [06] name=APP start=0 size=13107200 sectors
  [07] name=APP_b start=0 size=13107200 sectors
  [08] name=CONF start=0 size=102400 sectors
  [09] name=DATA (fills to end)
Writing partitions
  Writing boot.img (size=49289216) to /dev/sda1 (size=134217728)...
  Writing kernel_tm5-orin-nx16-rev0.dtb (size=250113) to /dev/sda2 (size=786432)...
  Writing boot.img (size=49289216) to /dev/sda3 (size=134217728)...
  Writing kernel_tm5-orin-nx16-rev0.dtb (size=250113) to /dev/sda4 (size=786432)...
  Writing esp.img (size=67108864) to /dev/sda5 (size=67108864)...
ERR: cannot locate block device /dev/sda6
  Writing tm-core-image.ext4 (size=6710886400) to /dev/sda6 (size=)...
  Writing tm-core-image.ext4 (size=6710886400) to /dev/sda7 (size=6710886400)...
[OK: /dev/sda

I circumvented the error, by commenting out line 198 in make-sdcard. After that we can get it running by forcing it in the slot B.

Does anyone have any pointers on what could be the issue?

Edit: Added info on Orin-NX16.

[conradmenchine]

Hmmm... I've had luck by instead setting IMAGE_ROOTFS_EXTRA_SPACE. Not sure how yocto handles things differently under the hood, but I've been able to expand to the full size of the eMMC on an Orin

[joeced]

It seems it was a fluke - everything worked correctly after all. I had a "leftover" /dev/sda6 device in my system. I simply sudo rm /dev/sda6 - and then it subsequently worked again.

How I ended up with this "leftover" device, I have no idea.