Create Recovery Disk for Intel-based Terastation

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Extract the boot files for your device from the firmware using this method
Extract Boot Files from Stock Firmware

Create an mbr partiton table using fdisk with a single partition

Disk /dev/sdh: 3.7 GiB, 4005527552 bytes, 7823296 sectors
Units: sectors of 1 * 512 = 512 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disklabel type: dos
Disk identifier: 0xd140eaa0

Device     Boot Start    End Sectors  Size Id Type
/dev/sdh1  *     2048 206847  204800  100M  b W95 FAT32

format the partition with a fat32 filesystem (really can use whatever filesystem you want)

mkfs.vfat -F 32 -n RECOVERY /dev/sdh1

mount the partition

mkdir /mnt/recovery
mount /dev/sdh1 /mnt/recovery/

copy the boot files to the partition

cp *.buffalo /mnt/recovery/

install grub to the recovery disk (not the partition, the disk)

grub-install --force --no-floppy --boot-directory=/mnt/recovery /dev/sdh

create a grub.cfg which uses the boot files (use the filenames specific to your device)

set timeout=0
set default=0

set root='(hd0,msdos1)'

# attempt to
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

copy the grub.cfg to the grub

cp grub.cfg /mnt/recovery/grub/

unmount the recovery disk

umount /mnt/recovery

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