Thanks for your tip. I've spent multiple hours fiddling around and at least got a step further.
I've found out adding 'debug' to the append line in syslinux.cfg, the boot process prints some more info. Which is helpful in my case.
I added 'root=/dev/sda1' to syslinux.cfg and found out the drive is found and is mounted during boot.
[sda] Attached SCSI removable disk
VFS: Mounted root (vfat filesystem) readonly on device 8:1.
devtmpfs: error mounting -2
rodata_tests: all tests were successful
Run /sbin/init as init process
with arguments:
/sbin/init
with environment:
HOME=/
TERM=linux
BOOT_IMAGE=/bzimage
... same for /etc/init, /bin/init, /bin/sh ...
Kernel panic - not syncing: No working init found. Try passing init= option to kernel. See Linux Documentation/admin-guide/init.rst for guidance.
At least it tells me it *found* the usb disk. It mounted the device readonly and throws an error 'devtmpfs: error mounting'. To me it's unclear if devtmpfs related directly to failed mounting of the usb disk.
'No working init found'; I've read the documentation at https://www.kernel.org/doc/Documentation/admin-guide/init.rst which makes me believe the issue is either;
1) disk is available in boot process, but root FS cannot be mount (due to partition failure? /dev/sda1 isn't pointing to the right partition maybe?)
2) init binary doesn't exit on rootfs. I've tried to mount / open / inspect and bzcat bzimage, bzroot etc, but couldn't find a hint.
3) Binary cannot be loaded due to either architecture mismatch (i386 cs x86_64)
OR maybe the current shipped kernel dropped driver(s) / support for the hardware in my Mac Mini Server??