Create Recovery Disk for Intel-based Terastation

= Get the necessary tools/resources = First, extract the boot files for your device from the firmware using this method: Extract Boot Files from Stock Firmware

= Create disk image =

Grub-based image
Using a linux system with grub2 and xorriso installed.

Create a grub.cfg suitable for your device:
Terastation WVHL/QVHL/6VHL/8VHL/RVHL set timeout=0 set default=0

set root='(hd0)'

menuentry "Terastation WVHL/QVHL/6VHL/8VHL/RVHL EM Mode" { linux /vmlinuz-atom_d510.buffalo root=sde1 rw usbboot=yes mode=initilize ts4000=no acc=no initrd /initrd-atom_d510.buffalo }

Terastation 4000 Series set timeout=0 set default=0

set root='(hd0)'

menuentry "Terastation 4000 Series EM Mode" { linux /vmlinuz-atom_usi.buffalo root=sde1 rw usbboot=yes mode=initilize ts4000=yes acc=no initrd /initrd-atom_usi.buffalo }

Terastation 5000 Series set timeout=0 set default=0

set root='(hd0)'

menuentry "Terastation 5000 Series EM Mode" { linux /vmlinuz-atom_d510.buffalo root=sde1 rw usbboot=yes mode=initilize ts4000=no acc=no initrd /initrd-atom_d510.buffalo }

Create a directory tree to create the disk image from:
mkdir -p disk/boot/grub/

Add the boot files and the grub config file:
disk/initrd-atom_d510.buffalo disk/vmlinuz-atom_d510.buffalo disk/boot/grub/grub.cfg

Generate the iso file
grub-mkrescue -o ts-recovery.iso disk/

Create isolinux.cfg
isolinux.cfg: ui vesamenu.c32

TIMEOUT 50

label tsv menu label Terastation WVHL/QVHL/6VHL/8VHL/RVHL EM Mode menu default kernel /vmlinuz-atom_d510.buffalo initrd /initrd-atom_d510.buffalo append root=sde1 rw usbboot=yes mode=initilize ts4000=no acc=no

Create a directory tree to create the disk image from:
mkdir iso cp isolinux.cfg iso/ cp initrd-atom_d510.buffalo iso/ cp vmlinuz-atom_d510.buffalo iso/ cp "/usr/lib/ISOLINUX/isolinux.bin" iso/ cp "/usr/lib/syslinux/modules/bios/vesamenu.c32" iso/ cp "/usr/lib/syslinux/modules/bios/libcom32.c32" iso/ cp "/usr/lib/syslinux/modules/bios/libutil.c32" iso/ cp "/usr/lib/syslinux/modules/bios/ldlinux.c32" iso/

Generate the iso file
mkisofs -o ts-recovery.iso \ -b isolinux.bin -c boot.cat \ -no-emul-boot -boot-load-size 4 -boot-info-table \ iso

isohybrid ts-recovery.iso

= Copy the image to a usb drive = dd if=ts-recovery.iso of=/dev/sdx bs=4k

The disk is now ready to use to boot the device into EM mode for firmware installation