Been running 6.1.9 smoothly since it came out, stock with no plugins. I attempted to upgrade to 6.2 via the webGUI today, but when I stopped my array and then rebooted the server like it prompted me to, I couldn't get past the initial boot unRaid selection screen (I saw a new screen that contained the GUI boot option). No matter which option I tried (normal unRaid boot, unRaid safe boot without plugins), it would get stuck on loading /bzroot. It would just sit there and not move past that option.

 

I ejected the flash drive and plugged it into my Windows machine. I started to notice some issues with the Flash drive, Windows kept saying the device may not be working properly. I copied all the files onto my desktop, but the files in the "previous" folder (I'm assuming from the update via the webGUI) appear to have nothing in them (eg changes.txt says it's 18 KB but when I try to open it in Notepad, no text is displayed).

 

So after I copied the files off the Flash drive and noticed some weirdness, I decided to try installing 6.2 fresh the "old-school" way. I copied/overwrote files from the 6.2 download .zip. But then I noticed some files (namely files and sub directories under the "syslinux" folder) had flunky characters in their filename. It seems like I can manually create the folders on the Flash drive just fine. But copying them over from the .zip folder always ends up with corrupt files in that folder. See attached screenshot.

 

So it appears that I'm stuck, I can't seem to get the Flash drive to work correctly. I've tried to re-format the Flash drive and copy all the 6.2 files over with no avail. It says something to the effect of"can't find config file" when I boot. I have an older backup copy of the flash drive (a 6.1.7 from earlier this year, which I've added a drive to since), but when I format and use those files and boot it the screen just says "SYSLINUX 6.03 EDD".

 

Any thoughts on what to do? Think it's a bad Flash drive? I have an older (but hopefully better functioning) Flash drive that I could use right away.

I suspect that you have something seriously wrong with that Flash Drive.  I would suggest that you format the drive again but this time, uncheck the 'Quick Format' option.  It will take a while to format the drive as it will now write to every byte on the drive.  It will either complete the process or it will error out.

 

I assume that you have your unRAID key file somewhere beside that drive.  If you do, you can load up ver 6.2 onto a new Flash Drive.  Put the key file in the config folder and follow this procedure:

 

    https://lime-technology.com/replace-key/

Thanks Frank. I went ahead and used a different Flash drive, loaded 6.1.9 on it, with my Shares folder and .key and went through the replacement key process. I assigned the drives back up and did a sync on it. So now everything is back working again with 6.1.9. I may just wait a bit on trying to upgrade to 6.2. I'm sure it was mostly due to the Flash drive, but I've read a couple other threads having issues booting up and getting stuck on /bzroot during the loading process. Might wait to see if Limetech can replicate and/or fix this potential issue.