Try the following steps
- partition and format sdcard
$ sudo fdisk /dev/mmcblk1
Welcome to fdisk (util-linux 2.38.1).
Changes will remain in memory only, until you decide to write them.
Be careful before using the write command.
Command (m for help): o
Created a new DOS (MBR) disklabel with disk identifier 0x628d6005.
Command (m for help): n
Partition type
p primary (0 primary, 0 extended, 4 free)
e extended (container for logical partitions)
Select (default p): p
Partition number (1-4, default 1): 1
First sector (2048-62410751, default 2048):
Last sector, +/-sectors or +/-size{K,M,G,T,P} (2048-62410751, default 62410751):
Created a new partition 1 of type 'Linux' and of size 29.8 GiB.
Command (m for help): w
The partition table has been altered.
Calling ioctl() to re-read partition table.
Syncing disks.
$ sudo mkfs.ext4 /dev/mmcblk1p1
mke2fs 1.47.0 (5-Feb-2023)
Discarding device blocks: done
Creating filesystem with 7801088 4k blocks and 1954064 inodes
Filesystem UUID: 521e136a-86d6-482c-adf6-d0f0f3fc2433
Superblock backups stored on blocks:
32768, 98304, 163840, 229376, 294912, 819200, 884736, 1605632, 2654208,
4096000
Allocating group tables: done
Writing inode tables: done
Creating journal (32768 blocks): done
Writing superblocks and filesystem accounting information: done
- Set sdcard to mount on boot
$ sudo nano /etc/fstab
Scroll to a empty line at the bottom using arrow keys and add the following
/dev/mmcblk1p1 /usr/share/hassio ext4 defaults,noatime 0 0
Press Ctrl+o to save and Ctrl+x to exit.
- Mount sdcard to /mnt
sudo mount /dev/mmcblk1p1 /mnt
- Copy the old files from /usr/share/hassio to /mnt
sudo rsync -av /usr/share/hassio/* /mnt/
- Reboot.
sudo reboot