Linux macOS Recovery USB Creator

Create a bootable macOS Recovery USB from any major Linux distro (Debian/Ubuntu, Fedora, Arch, etc.). Targets Monterey (12.6) by default; adapts for Ventura/Sonoma via fetch-macOS.py. Uses Apple's BaseSystem.dmg for legal, direct recovery boot—no full installer bloat.

Tested Nov 2025 on Ubuntu 25.10 (sudo-rs default), Fedora 42, Arch rolling. Outputs ~3GB raw IMG; dd to USB. Bypasses Internet Recovery flakes (e.g., stuck on Sierra).

Prereqs

• Git, Python 3, wget/curl.
• USB ≥16GB (gets wiped).
• ~20GB disk space.
• Stable net (downloads ~3GB).
• Root access (sudo/sudo-rs; no diff in usage).

Install Deps

Run the block for your distro. For xar: Use pkg mgr if available (e.g., apt on Ubuntu); fallback to source build.

Distro	Command
Debian/Ubuntu	sudo apt update && sudo apt install -y git python3 wget hfsprogs dmg2img build-essential autoconf libxml2-dev libssl-dev mac-fdisk-cross xar
Fedora	sudo dnf install -y git python3 wget hfsprogs dmg2img @development-tools libxml2-devel openssl-devel
Arch	sudo pacman -Syu --needed git python wget hfsprogs dmg2img base-devel libxml2 openssl

If xar not in repos (Fedora/Arch), build from source (fixes OpenSSL in newer libssl):

cd ~
git clone https://github.com/mackyle/xar
cd xar/xar  # Note: subdir has the goods
sed -i 's/OpenSSL_add_all_ciphers/OPENSSL_init_crypto/g' configure.ac
./autogen.sh --prefix=/usr/local
make
sudo make install  # Or sudo-rs if on Ubuntu 25.10+
cd ~  # xar --version to verify

Fetch & Prep BaseSystem

Clone fetch-macOS (KVM helpers; MIT-licensed).

git clone --depth 1 --recursive https://github.com/kholia/OSX-KVM.git
cd OSX-KVM
./fetch-macOS-v2.py  # Menu: 5 for Monterey (12.6); 6 Ventura, 7 Sonoma
cp BaseSystem.dmg ~/recovery/  # Or your dir
cd ~/recovery
dmg2img BaseSystem.dmg BaseSystem.img  # Expands to ~3GB raw

Burn to USB

ID your USB (whole device, not partition):

lsblk -o NAME,SIZE,TYPE  # e.g., sdb 16G disk

Burn (replace /dev/sdX; ~5min):

sudo dd if=BaseSystem.img of=/dev/sdX bs=4M status=progress && sync
sudo eject /dev/sdX  # Or udisksctl power-off -b /dev/sdX

Boot & Recover

• Insert USB on Mac.
• Restart + hold Option (⌥).
• Select EFI Boot/Recovery (~3GB volume).
• In Recovery: Disk Utility → new APFS vol (GUID scheme).
• Reinstall macOS → downloads fresh (needs net).

Troubleshooting

Issue	Fix
xar sed fails	Ensure in xar/xar; re-clone if git hiccup.
fetch.py hangs	VPN/proxy; retry option. For Sequoia (15), use 8—needs signed EFI (may fail on old hardware).
dd "No space"	Use ≥16GB USB; verify lsblk.
No boot menu	Reset Mac NVRAM (Cmd+Opt+P+R at chime); try USB 3.0 port. Alt: resize BaseSystem p2 with parted if needed (rare).
sudo-rs weird logs	Ubuntu 25.10+ default (Rust impl); ignore—behavior identical to sudo.

Notes

• For full installer: Extend with macos_usb repo (github.com/notthebee/macos_usb); but Recovery suffices for wipes/reinstalls.
• Legal: Pulls from swscan.apple.com—Apple's public mirrors.

Credits

• OSX-KVM for fetch.py.
• coolaj86 Gist for BaseSystem direct-dd (core hack).
• Tested: MacBook Air 2015 → Monterey clean install.