How to make a USB stick that will not freeze during the Lion install:
1. Obtain a $29 copy of Lion from the Apple store and download it to a working Mac and mount the image. Note: Lion automatically downloads into the Applications folder by default.
2. I then mounted it by right-clicking and then show package contents. Then I navigated to Contents > Shared Support to find the file called InstallESD.dmg to click on. This will then mount the file for you after it automatically verifies.
3. Now go and grab the xfail application from the tonycrapx86 website or his blogspot. Note: The reason why you want xfail rather than his unifail application is that xfail will create a clean flash drive without any boot loaders etc.
4. Once you have xfail downloaded and installed, insert your blank and pre-formated with the GUI partition table 8 gigabyte or larger flash drive.
5. When you launch and run xfail it will automatically find your mounted InstallESD.dmg and install it cleanly with all Base image and package files onto your 8 gigabyte USB stick.
6. When the process is complete, open your USB stick and navigate to the System > Library > Extensions (S/L/E) folder where you need to copy (overwrite) 3 files. These files from 10.6.7 are AppleACPIPlatform.kext (Version 1.35) - IOPCIFamily.kext (Version 2.6) and IO80211Family.kext (Version 3.14). All 3 files are attached in the ACPI + PCI + 80211 - 10.6.7.zip file. Use the Kext Wizard to do the copying for you and you can place a check mark to back up the 3 Kext files you are replacing. By copying (overwriting) with these 3 files, Lion will install on your D530 using your USB stick without freezing. As a side note once Lion 7.3 is up and running, I found out that you can upgrade IO80211Family.kext to a tiny bit higher Version 3.2 which comes from 10.6.8.
7. After these 3 files copied successfully, I then did repair permissions on the (S/L/E) folder of the USB install stick using Kext Wizard to play it safe.
8. I then installed the boot loader to the USB stick using multifail from tonycrapx86. Even though this is a Lion install, I found it easier to use his multifail for Snow Leopard (Version 3.10.1) Upon launching it, I ensured that the location was my USB stick and I only selected the chimera (chameleon, stolen and rebranded) v1.7.0 r1394 bootloader (located under Drivers & Bootloaders). Then in the Kexts and Enablers section under Miscellaneous choose FakeSMC.kext, NullCPUPowerManagement.kext and then PS2/Mouse support to have AppleACPIPS2Nub.kext and ApplePS2Controller for a total of 4 files. The last selection is very important as it defines the System Definition you need to use. Under Customization, select System Definitions and go to Mac Pro. In there you will select MacPro3,1 where you then allow multifail to install all selected items.
9. You will now have a bootable USB Stick with 4 Kext files, a boot loader and a MacPro3,1 system definition where your Lion install will not freeze on you Dell Latitude D530 during install.
10. After Lion is installed, you may have to play a little to get it to come up. For instance, I only had to use the - v (verbose mode) at the boot option prompt to get it up. I didn't need any other switches or even try safe mode (- x). Lion should boot within the 2nd or 3rd attempt.
11. After Lion 7.3 is up on your Latitude D530, here is the exact copy of my Extra Folder I created manually (D530_Extra.zip). Within it I went and grabbed DSDT.aml out of the EDP 2.1 package which had an update for the D530 along with 9 Kext files - AppleACPIBatteryManager.kext - AppleACPIPS2Nub.kext - ApplePS2Controller - FakeSMC.kext - IntelCPUMonitor.kext - VoodooHDA.kext - ApplePS2Keyboard.kext and ApplePS2Mouse.kext (I needed these two PS2 files from the EDP 2.2 package to get tapping to select items working on my touchpad) Lastly, included is the AppleBCM5751Ethernet.kext from the EDP 2.2 package as this version had the 1673 Device ID for my Integrated (BCM-5755M) Intel Gigabyte LAN.
In addition, I found that installing these Kext files in the /Extra folder is fine and there was no need to mess with or install them into the (S/L/E) folder. Also note that there is no NullCPUPowerManagement.kext file included as it is not needed.
12. The content of the included org.chameleon.Boot.plist is: (I'm using 1024x768x32 for my D530 XGA display (last model to have square screen)
<key>Graphics Mode</key> <string>1024x768x32</string>
<key>Kernel Flags</key> <string>arch=i386</string>
13. It's pretty much the same that is included within EDP 2.1 and 2.2 for the D530 except that I took out the USB fix = Yes lines as all my usb ports never had any glitch with 10.6.6, 10.6.8 and now 10.7.3. In addition, I didn't have to use the sleep enabler Kext or add these lines to the org.chameleon.Boot.plist file.
14. I repeat, I have sleep working perfectly in Lion 10.73 on my D530 and did it all manually without using the edp command line tool to delete the hibernation file and then add the sleep enabler Kext etc.
15. The content of the included smbios.plist is:
<key>SMfamily</key> <string>Mac Pro</string>
<key>SMbiosversion</key> <string>Dell Latitude D530</string>
16. I then performed the tiny upgrade of IO80211Family.kext from Version 3.1.4 from 10.6.7 to Version 3.2 which comes from 10.6.8. This 3.2 update replaced the older one contained in the (S/L/E) folder using Kext Wizard. I then repaired permissions with Kext Wizard on both Extra and the (S/L/E) folder.and then also repaired permissions using the option to do so within Disk Utility to play it double safe. This 10.6.8 file is attached in the IO80211Family.kext - 10.6.8.zip file.
17. Like I began this post with, I have my D530 running Lion 7.3 with translucent menu bar, DVD playback, YouTube videos working and Sleep. I'm at 99.9% all done up and running Lion 7.3 with even the later updates applied as well. I have not yet played with or tested SpeedStep and will begin by includng the above Generate P and C state lines into the org.chameleon.Boot.plist file.
18. The reason I went to MacPro3,1 in this tutorial for Lion 10.7.3 is because multifail (Lion Edition) notes to to do so. Thus the D530 is now cracked and you can remove all notations in red regarding not tested etc and that 10.6.8 and 10.7.3 works beautiful. Just update the default smbios.plist files included in the EDP packages for the D530 as noted above. Note. I did not test the EDP 2.2 package only the EDP 2.1. However I did have to use the ApplePS2Keyboard.kext and ApplePS2Mouse.kext from the EDP 2.2 package to get the tapping to select items working on my D530 touch pad.
Final Note: Even though I am using the D530 DSDT.ami file - Before I included it I did not need any help the system "reboot" Kext files such as EvOreboot.kext or OpenHaltRestart.kext. I also did not need AppleHDADisabler.kext or any let's modify the Lion RTC Kext. My system started, re-started and shutdown instantly without these files before and after implementing the D530 DSDT.ami file. I also didn't need the VoodooTSCSync.kext nor any port injectors such as AHCIPortInjector.kextI or AppleIntelPIIXATA.kext nor the PlatformUUID.kext. And yes, I run my system in ATA mode to save time in swapping out my Windows separate hard drives. I hope this post helps all. - Best, Darren
Mountain Lion Preview here I come. I believe 10.6.2 had the 64-bit X3100 drivers...