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mke2fs creates and sizes the output file before it populates it, so a build that failed mid-way left a recent-looking image full of zeros at the final name - newer than the tarball, and trusted by the freshness check forever after. The first run after the libarchive fix booted exactly that wreckage: EXT4-fs "Can't find ext4 filesystem". The build now lands in a sibling .part file and renames over the image only on success, and the freshness check additionally requires the ext4 superblock magic (s_magic, at byte 1080) before trusting an existing image - caches already carrying wreckage rebuild over it on the next run instead of needing a manual clean.