Thanks Peter.
You solved my problem again. It would have taken me a while to figure out what was happening. Again, this stuff all makes sense if you know how it works.
A couple of things that are probably worth mentioning:
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After I fixed the root partition issue, booting was fine but the jupyter service wouldn’t consistently start. It turns out that when the I “wrote” the *.img file to the SD card, the root partition ended up being full which caused all sorts of funny issues. Luckily, I had already looked at the resizefs package and I just added that to the custom board build. Now things look good. I’ll have to play with it and try some overlays.
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Even though I’m not using the dist tarball it is still trying to copy it to the output so I get an error during the custom build. Since I’m using the prebuilt image this doesn’t cause a problem but it shouldn’t produce an error in this case.
Anyway, thanks again. I’m sure glad that you documented this process and have been available to answer my questions.
Ralph