On Sat, 8 Jun 2013, Glen Barber wrote:

The problem is creating the gpart(8) partition scheme on the md(4)
device.

Below follows script(1) output of what the make-memstick.sh script does:

 Script started on Sun Jun  9 00:41:08 2013
 root@snap:/snap/releng # chroot /snap/releng/10-i386-snap
 root@snap:/ # cd /usr/obj/usr/src/release
 root@snap:/usr/obj/usr/src/release # echo \
   '/dev/ufs/FreeBSD_Install / ufs ro,noatime 1 1' > release/etc/fstab
 root@snap:/usr/obj/usr/src/release # makefs -B \
   little -o label=FreeBSD_Install test.img release
 Calculated size of `test.img': 649420800 bytes, 12922 inodes
 Extent size set to 8192
 test.img: 619.3MB (1268400 sectors) block size 8192, fragment size 1024
        using 12 cylinder groups of 54.40MB, 6963 blks, 1152 inodes.
 super-block backups (for fsck -b #) at:
       32,  111440,  222848,  334256,  445664,  557072,  668480,  779888,
   891296, 1002704, 1114112, 1225520,
 Populating `test.img'
 Image `test.img' complete
 root@snap:/usr/obj/usr/src/release # mdconfig -a -t vnode -f test.img
 md0

All fine up until this point.  Now the gpart(8) partition is created:

 root@snap:/usr/obj/usr/src/release # gpart create -s BSD /dev/md0
 gpart: Inappropriate ioctl for device
 root@snap:/usr/obj/usr/src/release # gpart list md0
 Segmentation fault (core dumped)

This might be a good time to stop using a bare bsdlabel (aka "dangerously dedicated"). MBR plus bsdlabel is not great, but more widely understood, and other operating systems will at least recognize the MBR slice. I can help with this if needed.
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