diff --git a/.github/workflows/deploy-pyinstaller.yml b/.github/workflows/deploy-pyinstaller.yml
index c46d638c..e12dac9f 100644
--- a/.github/workflows/deploy-pyinstaller.yml
+++ b/.github/workflows/deploy-pyinstaller.yml
@@ -8,10 +8,10 @@ jobs:
   build:
     strategy:
       matrix:
-        os: [ubuntu-latest, macos-latest, windows-latest]
+        os: [ubuntu-22.04, macos-latest, windows-latest]
         torch_variant: [cpu, cu129]
         include:
-          - os: ubuntu-latest
+          - os: ubuntu-22.04
             platform: linux-x64
             build_script: ./INSTALL/pyinstaller/make_pyinstaller_image.sh
             executable_ext: ""
diff --git a/INSTALL/pyinstaller/make_pyinstaller_image.ps1 b/INSTALL/pyinstaller/make_pyinstaller_image.ps1
index 402b0f3f..afa387dc 100644
--- a/INSTALL/pyinstaller/make_pyinstaller_image.ps1
+++ b/INSTALL/pyinstaller/make_pyinstaller_image.ps1
@@ -31,11 +31,14 @@ switch ($TorchVariant) {
 }
 
 # Set PyInstaller mode based on torch variant
-if ($TorchVariant -eq "cpu") {
-    $pyinstallerMode = "--onefile"
-} else {
-    $pyinstallerMode = "--onedir"
-}
+# if ($TorchVariant -eq "cpu") {
+#     $pyinstallerMode = "--onefile"
+# } else {
+#     $pyinstallerMode = "--onedir"
+# }
+
+# --onefile has too many problems with large packages like torch!
+$pyinstallerMode = "--onedir"
 
 # Upgrade build tools and hooks
 python -m pip install -U pip wheel setuptools
diff --git a/INSTALL/pyinstaller/make_pyinstaller_image.sh b/INSTALL/pyinstaller/make_pyinstaller_image.sh
index 8181496d..8a6be27a 100755
--- a/INSTALL/pyinstaller/make_pyinstaller_image.sh
+++ b/INSTALL/pyinstaller/make_pyinstaller_image.sh
@@ -35,8 +35,9 @@ fi
 # Set PyInstaller mode based on torch variant and platform
 if [[ "$MACOS_APP" == true ]]; then
     PYINSTALLER_MODE="--windowed"
-elif [[ "$TORCH_VARIANT" == cpu ]]; then
-    PYINSTALLER_MODE="--onefile"
+# always use --onedir for CPU builds to avoid startup issues
+# elif [[ "$TORCH_VARIANT" == cpu ]]; then
+#     PYINSTALLER_MODE="--onefile"
 else
     PYINSTALLER_MODE="--onedir"
 fi
@@ -140,7 +141,8 @@ if [[ "$MACOS_APP" == true ]]; then
     LAUNCHER="$MACOS_DIR/run_in_terminal.sh"
     cat > "$LAUNCHER" <<EOF
 #!/bin/bash
-exec osascript -e 'tell application "Terminal" to do script "'"$MACOS_DIR/$BIN_NAME"'"'
+PWD=$(dirname "$0")
+exec osascript -e 'tell application "Terminal" to do script "'"$PWD/$BIN_NAME"'"'
 EOF
     chmod +x "$LAUNCHER"