Creates Bootable USB for Mac OS Lion to Monterey (Excluding Mavericks)

Install_USB_Maker.sh

#!/usr/bin/env bash

# Install_USB_Maker.sh
# Copyright (c) 2020 - 2023 Dayo Akanji
# - dakanji@users.sourceforge.net
# Portions Copyright (c) Jeff Geerling
# - https://github.com/geerlingguy/macos-virtualbox-vm/blob/master/LICENSE
#
# MIT License

# Derived from:
#    * https://apple.stackexchange.com/a/389830
#    * https://github.com/geerlingguy/macos-virtualbox-vm/blob/master/prepare-iso.sh
#
# 1. Download Lion to Monterey (Excluding Mavericks)
#    * From    : https://support.apple.com/HT211683 (Lion to Sierra or Links to App Store)
#    *         : https://github.com/corpnewt/gibMacOS (High Sierra to Monterey)
# 2. Use Disk Utility to format a USB stick partition:
#    * Name    : Install_USB_Maker
#    * Size    : Easiest to assume 16 GB but see details below
#    *         : 08 GB (Min) For Lion to Sierra (if via Install DMG)
#    *         : 16 GB (Min) For Yosemite to Sierra (if via Installer App)
#    *         : 16 GB (Min) For High Sierra to Monterey (Always Installer App)
#    * Format  : Mac OS Extended (Journaled)
# 3. Make the downloaded "Install" package available to this script
#    * For Lion to Sierra:
#    *     Mount the downloaded "Install DMG" file
#    *     Close the Finder window for the DMG if displayed
#    * For High Sierra to Monterey:
#    *     Place the install app in the 'Applications' folder
#    *     This can be done manually or by running the downloaded package
#    *     Placing manually in the folder containing this script also works
#    *     Installer Apps in the folder containing this script take precedence
#    * For Yosemite to Sierra (Alternative Option):
#    *     Place the install app in the 'Applications' folder
#    *     This can be done manually or by running the downloaded package
#    *     Placing manually in the folder containing this script also works
#    *     Installer Apps in the folder containing this script take precedence
# 4. Execute "chmod +x /Path/to/this/script/file" without quotes and then run this script file
# 5. Install Mac OS with the USB Installer created by the script
#    * Name    : {{MAC_OS_NAME}} Installer


## CUSTOM COLOURS ##
msg_status() {
	echo -e "\033[0;35m$1\033[0m"
}
msg_info() {
	echo -e "\033[0;33m$1\033[0m"
}
msg_error() {
	echo -e "\033[0;31m$1\033[0m"
}


# createISO by Jeff Geerling as modified by Dayo Akanji
# This function creates the ISO image.
# Inputs:  $1 = The name of the installer - located in Applications folder or local folder/PATH.
#          $2 = The Name of the ISO to be created.
function createISO() {
	# Realign 'TMP_STR' as changed before calling this function
	TMP_STR='NotSet'

	if [ $# -eq 2 ] ; then
		local installerAppName
		local isoName
		local error
		local SparseImageFile
		local InstallAppVol
		local InstallAppBaseSystem

		if [ -e "${SCRIPT_DIR}/${installerAppName}" ] ; then
			installerAppName="${SCRIPT_DIR}/${1}"
		elif [ -e "/Applications/${installerAppName}" ] ; then
			installerAppName="/Applications/${1}"
		else
			echo; echo
			msg_info 'ERROR!!'
			msg_error "Could Not Find Installer App}"
			runExit 'Error' ;
		fi
		isoName="${2}"
		error=0
		SparseImageFile="${INSTALL_TEMP}/${isoName}.sparseimage"
		InstallAppVol='/Volumes/install_app'
		InstallAppBaseSystem="${installerAppName}/Contents/SharedSupport/BaseSystem"

		sudo -v
		msg_status "STEP 01 of 16: Create a Blank 16GB Single Partition Apple Partition Map ISO Image"
		# Create INSTALL_TEMP folder
		mkdir -p "${INSTALL_TEMP}"
		# Just in case - delete any previous sparseimage
		[ -e "${SparseImageFile}" ] && rm -f "${SparseImageFile}"
		# increased size to 16G - 8G is too small for Catalina
		hdiutil create -o "${INSTALL_TEMP}/${isoName}" -size 16g -layout SPUD -fs HFS+J -type SPARSE

		sudo -v; echo
		msg_status "STEP 02 of 16: Mount Installer Image"
		if [ "${isoName}" == "Monterey" ] || [ "${isoName}" == "BigSur" ] ; then
			hdiutil attach "${SparseImageFile}" -noverify -nobrowse -mountpoint  "${InstallAppVol}"
		elif [ -e "${SCRIPT_DIR}/${installerAppName}" ] ; then
			hdiutil attach "${installerAppName}/Contents/SharedSupport/InstallESD.dmg" -noverify -nobrowse -mountpoint  "${InstallAppVol}"
			error=$?
		else
			error=1
		fi

		if [ ${error} -ne 0 ] ; then
			echo; echo
			msg_info 'ERROR!!'
			msg_error "Failed to mount the InstallESD.dmg from the installer at ${installerAppName}"
			msg_error "Exiting on 'Error Code: ${error}'"
			runExit 'Error' ;
		fi

		sudo -v; echo
		msg_status "STEP 03 of 16: Mount Sparse Bundle for Package Addition"
		if [ "${isoName}" == "Monterey" ] || [ "${isoName}" == "BigSur" ] ; then
			echo "N/A ... Skipped for ${INSTALL_NAME}"
		else
			hdiutil attach "${SparseImageFile}" -noverify -nobrowse -mountpoint '/Volumes/install_build'
		fi

		sudo -v; echo
		msg_status "STEP 04 of 16: Restore Base System into '${isoName}' ISO Image"
		if [ "${isoName}" == "Monterey" ] || [ "${isoName}" == "BigSur" ] ; then
			echo "N/A ... Skipped for ${INSTALL_NAME}"
		elif [ "${isoName}" == "Catalina" ] || [ "${isoName}" == "Mojave" ] || [ "${isoName}" == "HighSierra" ] ; then
			# Note by Jeff Geerling
			#following asr command returns an error and prints:
			#"Personalization succeeded"
			#"asr: Couldn't personalize volume /Volumes/macOS Base System - Operation not permitted"
			#I disabled SIP and the error still occurs.
			#This was reported in Issue #73 for Mojave
			#I added ||true for now to prevent the script from exiting as the steps that follow still seem to work fine for Catalina
			sudo asr restore -source  "${InstallAppBaseSystem}.dmg" -target '/Volumes/install_build' -noprompt -noverify -erase  || true
		else
			sudo asr restore -source  "${InstallAppVol}/BaseSystem.dmg" -target '/Volumes/install_build' -noprompt -noverify -erase
		fi

		sudo -v; echo
		msg_status "STEP 05 of 16: Remove Package Link and Replace with Actual Files"
		if [ "${isoName}" == "Monterey" ] || [ "${isoName}" == "BigSur" ] ; then
			echo "N/A ... Skipped for ${INSTALL_NAME}"
		elif [ "${isoName}" == "Catalina" ] || [ "${isoName}" == "Mojave" ] || [ "${isoName}" == "HighSierra" ] ; then
			ditto -V  "${InstallAppVol}/Packages" "${VOL_BASE_DIR}/System/Installation/"
		else
			rm -v "${VOL_BASE_DIR}/System/Installation/Packages"
			cp -rpv "${InstallAppVol}/Packages" "${VOL_BASE_DIR}/System/Installation/"
		fi

		sudo -v; echo
		msg_status "STEP 06 of 16: Copy '${INSTALL_STICK}' Dependencies"
		msg_status 'NB: Type passwword and press "Enter" if prompted'
		msg_status '    Nothing will display when typing passwword'
		if [ "${isoName}" == "Monterey" ] || [ "${isoName}" == "BigSur" ] ; then
			hsudo "${installerAppName}/Contents/Resources/createinstallmedia" --volume "${InstallAppVol}" --nointeraction
		elif [ "${isoName}" == "Catalina" ] || [ "${isoName}" == "Mojave" ] || [ "${isoName}" == "HighSierra" ] ; then
			ditto -V  "${InstallAppBaseSystem}.chunklist" "${VOL_BASE_SYS}.chunklist"
			ditto -V  "${InstallAppBaseSystem}.dmg" "${VOL_BASE_SYS}.dmg"
		else
			cp -rpv  "${InstallAppVol}/BaseSystem.chunklist" "${VOL_BASE_SYS}.chunklist"
			cp -rpv  "${InstallAppVol}/BaseSystem.dmg" "${VOL_BASE_SYS}.dmg"
		fi

		sudo -v; echo
		msg_status "STEP 07 of 16: Unmount Installer Image"
		if [ "${isoName}" == "Monterey" ] || [ "${isoName}" == "BigSur" ] ; then
			hdiutil detach "/Volumes/Install macOS ${INSTALL_NAME}" -force # NOTE: force because "Resource busy"
		else
			hdiutil detach  "${InstallAppVol}"
		fi

		sudo -v; echo
		msg_status 'STEP 08 of 16: Unmount Sparse Bundle'
		if [ "${isoName}" == "Monterey" ] || [ "${isoName}" == "BigSur" ] ; then
			echo "N/A ... Skipped for ${INSTALL_NAME}"
		else
			hdiutil detach "${VOL_BASE_DIR}/"
		fi

		sudo -v; echo
		msg_status 'STEP 09 of 16: Resize Sparse Bundle to Remove Free Space'
		hdiutil resize -size `hdiutil resize -limits "${SparseImageFile}" | tail -n 1 | awk '{ print $1 }'`b "${SparseImageFile}"

		sudo -v; echo
		msg_status "STEP 10 of 16: Convert '${isoName}' Sparse Bundle to ISO/CD Master"
		hdiutil convert "${SparseImageFile}" -format UDTO -o "${INSTALL_TEMP}/${isoName}"

		sudo -v; echo
		msg_status 'STEP 11 of 16: Remove Sparse Bundle'
		rm -v "${SparseImageFile}"

		sudo -v; echo
		msg_status 'STEP 12 of 16: Convert ISO/CD Master to Regular Image'
		mv -v "${INSTALL_TEMP}/${isoName}.cdr" "${INSTALL_TEMP}/${isoName}.iso"

		sudo -v; echo
		msg_status "STEP 13 of 16: Get Disk ID for '${INSTALL_ID}' ..."
		DiskID=$( diskutil info "${INSTALL_ID}" | grep 'Device Node' )
		TmpDiskInfo=${DiskID##*/}
		DiskID=${TmpDiskInfo##*( )}
		echo "Disk ID = '${DiskID}'"

		sudo -v; echo
		msg_status "STEP 14 of 16: Create a bootable installer in '${INSTALL_ID}' ..."
		msg_status 'NB: This takes a while to complete'
		msg_status '    Type passwword and press "Enter" if prompted'
		msg_status '    Nothing will display when typing passwword'
		sudo dd if="${INSTALL_TEMP}/${isoName}.iso" of="/dev/r${DiskID}" bs=1m

		sudo -v; echo
		msg_status "STEP 15 of 16: Rename '${INSTALL_ID}' as '${INSTALL_STICK}' ..."
		msg_status 'NB: Type passwword and press "Enter" if prompted'
		msg_status '    Nothing will display when typing passwword'
		sudo diskutil rename "${INSTALL_ID}" "${INSTALL_STICK}"

		sudo -v; echo
		msg_status "STEP 16 of 16: Finishing"
		msg_status 'NB: This takes a while to complete'
		cd "${HOME}" || true
		rm -rf "${INSTALL_TEMP}" || true
		diskutil eject "${INSTALL_STICK}" || true
		runExit ;
	fi
}

# installerExists by Jeff Geerling
# Returns 0 if the installer was found locally or in '/Applications'.  1 if not.
function installerExists() {
	local installerAppName
	local result

	installerAppName="${1}"
	result=1
	if [ -e "${SCRIPT_DIR}/${installerAppName}" ] ; then
		result=0
	elif [ -e "/Applications/${installerAppName}" ] ; then
		result=0
	fi
	return ${result}
}


## EXIT HANDLER ##
runExit() {
	flag=${1:-Norm}
	if [ "${flag}" == 'Norm' ] ; then
		echo; echo
		msg_info 'All Done!'
	fi
	echo; echo
	msg_info '################################'
	msg_info ' ##  Create Mac OS Install USB ##'
	msg_info '  ################################'
	echo; echo
	exit 0
}

## ERROR HANDLER ##
runErr() {
	echo; echo
	msg_info "Runtime Error!!"
	msg_error "Could Not Create USB Installer"
	echo; echo
	rm -rf "${INSTALL_TEMP}"
    exit 1
}
trap runErr ERR


##
## Start Procedural Code
##
INSTALL_STICK='NotSet'
INSTALL_BASIC='Install OS X'
INSTALL_NAME='NotSet'
INSTALL_TEMP='/tmp/VersionOSX'
INSTALL_BASE='OS X Base System'
INSTALL_APP='Mac OS Install'
INSTALL_ESD='/Volumes/TMP_ESD'
INSTALL_ID='Install_USB_Maker'
INSTALL_X='InstallMacOSX'
TYPE_OSX="macOS"
TMP_STR='NotSet'
USE_APP='NotSet'
VOL_BASE_SYS='NotSet'
VOL_BASE_DIR='NotSet'

# Resolve TMP_SOURCE until the file is no longer a symlink
TMP_SOURCE=${BASH_SOURCE[0]}
while [ -L "${TMP_SOURCE}" ]; do
	DIR=$( cd -P "$( dirname "${TMP_SOURCE}" )" >/dev/null 2>&1 && pwd )
	TMP_SOURCE=$(readlink "${TMP_SOURCE}")
	# if ${TMP_SOURCE} is relative symlink, resolve relative to symlink file location
	[[ ${TMP_SOURCE} != /* ]] && TMP_SOURCE=${DIR}/${TMP_SOURCE}
done
SCRIPT_DIR=$( cd -P "$( dirname "${TMP_SOURCE}" )" >/dev/null 2>&1 && pwd )

if [ ! -d "/Volumes/${INSTALL_ID}" ] ; then
	err_msg="Connect a correctly sized USB stick labelled as '${INSTALL_ID}' and rerun this script."
	echo; echo
	msg_info 'ERROR!!'
	msg_error "${err_msg}"
	echo; echo
	exit 1
fi

sudo clear
echo; echo
msg_info '  ################################'
msg_info ' ##  Create Mac OS Install USB ##'
msg_info '################################'

echo; echo
msg_info '## STAGE 1 of 4: Confirm Install Target ##'
msg_info '------------------------------------------'
msg_status 'STEP 01 of 02: Get Mac OS Target'
PS3='Enter Corresponding Number for Mac OS Version or Exit: '
options=("Monterey" "Big Sur" "Catalina" "Mojave" "High Sierra" "Sierra" "El Capitan" "Yosemite" "Mavericks" "Mountain Lion" "Lion" "Exit")
select opt in "${options[@]}"
do
	case $opt in
		"Monterey" | "Big Sur" | "Catalina" | "Mojave" | "High Sierra")
			INSTALL_NAME="${opt}"
			USE_APP='True'
        break
        ;;
    	"Sierra")
			INSTALL_X='InstallOS'
			INSTALL_NAME="${opt}"
			USE_APP='Maybe'
			INSTALL_BASIC='Install macOS'
			INSTALL_APP="Install Mac OS ${INSTALL_NAME}.app"
        break
        ;;
    	"El Capitan" | "Yosemite")
			INSTALL_NAME="${opt}"
			USE_APP='Maybe'
			INSTALL_APP="Install Mac OS X ${INSTALL_NAME}.app"
        break
        ;;
		"Mountain Lion" | "Lion")
			INSTALL_NAME="${opt}"
			USE_APP='False'
			INSTALL_BASE='Mac OS X Base System'
			INSTALL_BASIC='Install Mac OS X'
			INSTALL_APP="Install OS X ${INSTALL_NAME}.app"
		break
        ;;
		"Mavericks")
			TMP_STR='Exit'
			INSTALL_NAME="${opt}"
		break
        ;;
        "Exit")
			TMP_STR='Exit'
        break
        ;;
        *)
			echo; echo
			msg_info 'ERROR!!'
            msg_error "Invalid Selection:- '${REPLY}'"
			echo; echo
			exit 1
        ;;
    esac
done

echo
msg_status "STEP 02 of 02: Returned '${INSTALL_NAME}'"
if [ "${TMP_STR}" == 'Exit' ] ; then
	if [ "${INSTALL_NAME}" == 'Mavericks' ] ; then
		echo; echo
		msg_info 'NOTE'
		msg_status "Mavericks Installer is not Supported"
	fi
    runExit 'Exit' ;
fi
TMP_STR='NotSet'
INSTALL_STICK="${INSTALL_NAME} Installer"

echo
msg_info 'Completed Stage 1'

echo; echo
msg_info '## STAGE 2 of 4: Confirm Prerequisites ##'
msg_info '-----------------------------------------'
gotError="False"
msg_status "STEP 01 of 01: Validate Misc ..."
# Check if using installer app for Yosemite to Sierra
if [ "${USE_APP}" == 'Maybe' ] ; then
	USE_APP='False'
	if [ "${INSTALL_NAME}" == 'Sierra' ] ; then
		TMP_STR='macOS'
	elif [ "${INSTALL_NAME}" == 'El Capitan' ] || [ "${INSTALL_NAME}" == 'Yosemite' ] ; then
		TMP_STR='OS X'
	fi
	if [ "${TMP_STR}" != 'NotSet' ] ; then
		if installerExists "Install ${TMP_STR} ${INSTALL_NAME}.app" ; then
			USE_APP='True'
		fi
	fi
fi
TMP_STR='NotSet'

if [ "${USE_APP}" == 'False' ] ; then
	# Ensure DMG is mounted
	if [ ! -d "/Volumes/${INSTALL_BASIC}" ] ; then
		err_msg="Mount the '${INSTALL_X}.dmg' file and rerun this script."
		gotError="True"
	fi
else
	# Note by Jeff Geerling
	# Eject installer disks in case opened after download from App Store
	# grep "partition_scheme" because "partition" finds too many lines
	for disk in $(hdiutil info | grep /dev/disk | grep partition_scheme | cut -f 1); do
		hdiutil detach -force ${disk}
	done
fi

# Error/Exit Handling
if [ "${gotError}" == 'True' ] ; then
	echo; echo
	msg_info 'ERROR!!'
	msg_error "${err_msg}"
	runExit 'Error' ;
fi

echo
msg_info 'Completed Stage 2'

if [ "${USE_APP}" == 'True' ] ; then
	echo; echo
	msg_info '## STAGE 3 of 4: Find Installer ##'
	msg_info '----------------------------------'
	msg_status "STEP 01 of 01: Checking for Installer App ..."
	if [[ "${INSTALL_NAME}" == "Monterey" || "${INSTALL_NAME}" == "Big Sur" || "${INSTALL_NAME}" == "Catalina" || "${INSTALL_NAME}" == "Mojave" ]] ; then
		if installerExists "Install macOS ${INSTALL_NAME}.app" ; then
			TMP_STR='macOS'
		fi
	elif [[ "${INSTALL_NAME}" == "High Sierra" || "${INSTALL_NAME}" == "Sierra" ]] ; then
		# DA-TAG: The Sierras are odd with 'macOS' app name but 'OS X' elsewhere
		if installerExists "Install macOS ${INSTALL_NAME}.app" ; then
			TMP_STR='OS X'
		fi
	elif [[ "${INSTALL_NAME}" == "El Capitan" || "${INSTALL_NAME}" == "Yosemite" ]] ; then
		if installerExists "Install OS X ${INSTALL_NAME}.app" ; then
			TMP_STR='OS X'
		fi
	fi
	if [ "${TMP_STR}" == 'NotSet' ] ; then
		echo; echo
		msg_info 'ERROR!!'
		msg_error "Could not find valid installer app file"
		runExit 'Error' ;
	fi
	echo "Found Installer App for ${INSTALL_NAME}"
	VOL_BASE_DIR="/Volumes/${TMP_STR} Base System"
	VOL_BASE_SYS="${VOL_BASE_DIR}/BaseSystem"
	TMP_STR='NotSet'

	echo
	msg_info 'Completed Stage 3'

	echo; echo
	msg_info '## STAGE 4 of 4: Create Bootable USB ##'
	msg_info '---------------------------------------'
	# Remove Spaces in 'INSTALL_NAME' and use as ISO name
	# TMP_STR is realinged in createISO
	TMP_STR=$( echo "${INSTALL_NAME}" | sed 's/ //g' )
	sudo -v; createISO "Install ${TYPE_OSX} ${INSTALL_NAME}.app" "${TMP_STR}"
else
	echo; echo
	msg_info '## STAGE 3 of 4: Deconstruct Installer ##'
	msg_info '-----------------------------------------'
	msg_status "STEP 01 of 05: Clearing ${INSTALL_TEMP} ..."
	rm -rfv "${INSTALL_TEMP}"

	sudo -v; echo
	msg_status "STEP 02 of 05: Creating ${INSTALL_TEMP} ..."
	msg_info 'NB: This takes a while to complete'
	pkgutil --expand "/Volumes/${INSTALL_BASIC}/${INSTALL_X}.pkg" "${INSTALL_TEMP}"

	sudo -v; echo
	msg_status "STEP 03 of 05: Ejecting ${INSTALL_BASIC} ..."
	diskutil eject "${INSTALL_BASIC}"

	sudo -v; echo
	msg_status 'STEP 04 of 05: Preparing and Attaching InstallESD DMG ...'
	hdiutil attach "${INSTALL_TEMP}/${INSTALL_X}.pkg/InstallESD.dmg"  -noverify -nobrowse -mountpoint "${INSTALL_ESD}"

	sudo -v; echo
	msg_status 'STEP 05 of 05: Preparing and Aligning BaseSystem DMG ...'
	msg_info 'NB: This takes a while to complete'
	msg_info '    Type passwword and press "Enter" if prompted'
	msg_info '    Nothing will display when typing passwword'
	sudo asr restore -source "${INSTALL_ESD}/BaseSystem.dmg" -target "/Volumes/${INSTALL_ID}" -noprompt -noverify -erase || true

	echo
	msg_info 'Completed Stage 3'

	echo; echo
	msg_info '## STAGE 4 of 4: Repackage Installer ##'
	msg_info '---------------------------------------'
	msg_status "STEP 01 of 09: Renaming ${INSTALL_BASE} ..."
	diskutil rename "${INSTALL_BASE}" "${INSTALL_STICK}"

	sudo -v; echo
	msg_status 'STEP 02 of 09: Clearing Installation Packages ...'
	rm -v "/Volumes/${INSTALL_STICK}/System/Installation/Packages"

	sudo -v; echo
	msg_status 'STEP 03 of 09: Reconstituting ESD Packages ...'
	msg_info 'NB: This takes a while to complete'
	cp -rpv "${INSTALL_ESD}/Packages" "/Volumes/${INSTALL_STICK}/System/Installation"

	sudo -v; echo
	msg_status 'STEP 04 of 09: Reconstituting BaseSystem Chunklist ...'
	cp -rpv "${INSTALL_ESD}/BaseSystem.chunklist" "/Volumes/${INSTALL_STICK}/"

	sudo -v; echo
	msg_status 'STEP 05 of 09: Reconstituting BaseSystem DMG ...'
	msg_info 'NB: This takes a while to complete'
	cp -rpv "${INSTALL_ESD}/BaseSystem.dmg" "/Volumes/${INSTALL_STICK}/"

	sudo -v; echo
	msg_status 'STEP 06 of 09: Detaching InstallESD DMG ...'
	hdiutil detach "${INSTALL_ESD}" || true

	sudo -v; echo
	msg_status 'STEP 07 of 09: Relabelling Volume ...'
	msg_status 'NB: Type passwword and press "Enter" if prompted'
	msg_status '    Nothing will display when typing passwword'
	sudo bless --folder "/Volumes/${INSTALL_STICK}/System/Library/CoreServices" --label "${INSTALL_STICK}"

	sudo -v; echo
	msg_status 'STEP 08 of 09: Updating VolumeIcon ...'
	InstallIcon="/Volumes/${INSTALL_STICK}/${INSTALL_APP}/Contents/Resources/InstallAssistant.icns"
	if [ -f "${InstallIcon}" ]; then
		cp -v "${InstallIcon}" "/Volumes/${INSTALL_STICK}/.VolumeIcon.icns"
	else
		echo 'Skipped ... VolumeIcon not found'
	fi

	sudo -v; echo
	msg_status 'STEP 09 of 09: Finishing ...'
	msg_info 'NB: This takes a while to complete'
	cd "${HOME}" || true
	rm -rf "${INSTALL_TEMP}" || true
	diskutil eject "${INSTALL_STICK}" || true

	echo
	msg_info 'Completed Stage 4'
	runExit ;
fi