Can confirm, not USB media. This was my first attempt at troubleshooting, formated to FAT 1GB mbr partition, used more than 1 USB drive to test. shaw256sum confirms.
Tried env default from uboot menu, no change.
Correct in your initramfs there's nothing under /lib/modules to modprobe.
I'm hesitant to erase and re-load the uboot environment as this chances bricking the device.
I'm wondering if the bad blocks reporting in bootlog is indicative of where the issue lies:
[ 1.179677] nand: 1024 MiB, SLC, erase size: 256 KiB, page size: 4096, OOB size: 224
[ 1.187453] iproc_nand 18026000.nand-controller: detected 1024MiB total, 256KiB blocks, 4KiB pages, 27B OOB, 8-bit, BCH-24 (1KiB sector)
[ 1.179677] nand: 1024 MiB, SLC, erase size: 256 KiB, page size: 4096, OOB size: 224
[ 1.187453] iproc_nand 18026000.nand-controller: detected 1024MiB total, 256KiB blocks, 4KiB pages, 27B OOB, 8-bit, BCH-24 (1KiB sector)
[ 1.200444] Bad block table found at page 262080, version 0x01
[ 1.206915] Bad block table found at page 262016, version 0x01
[ 1.219655] 7 fixed-partitions partitions found on MTD device brcmnand.0
Can you compare the sha256sum from the other mtd partitions?:
root@OpenWrt:~# sha256sum /dev/mtd0
342b68d1687a955255cd85dbeb6aa524a0d492cb43436b6a0d04aa3b1f1aef67 /dev/mtd0
root@OpenWrt:~# sha256sum /dev/mtd1
042b389daa71074fbad77c32375c01cca1e7153827e773131383c93f4dabc343 /dev/mtd1
root@OpenWrt:~# sha256sum /dev/mtd2
cc495db758c31cb3ffc87d491bed32b132f3d4faaa0e2391e13ed7d0a08c321d /dev/mtd2
root@OpenWrt:~# sha256sum /dev/mtd3
62a40424aea5e906f2c89f16f93d0868a3df6d992ac993a43953c7a944d185fb /dev/mtd3
root@OpenWrt:~# sha256sum /dev/mtd4
2962892d6b133903323b030661dfcd4f9373dda50fc0cadcc229d86860d03895 /dev/mtd4
root@OpenWrt:~# sha256sum /dev/mtd5
042b389daa71074fbad77c32375c01cca1e7153827e773131383c93f4dabc343 /dev/mtd5
This stuff is over my head so I'm struggling to come up with ways to troubleshoot. I've built a dev environment but unsure what all to select in the make config.
I can try to do some troubleshooting with the old clayface initramfs, but it kernel panics so time is limited to be able to attempt this. At boot, nothing shows up in ifconfig.
Crazy idea, what if usb storage is included in an intramfs image ... that would simplify the project for all going forward as we could write the sysupgrade bin directly?