Hi there, are you able to start with a known bootable minimal image (closest to the custom one you are building), mount the image boot partition and inject/overwrite the files in there with your copies?
Well, I had thought that I landed on etcher because that was the recommendation from the rpi folks. So I went over there to find a reference point and I was either mistaken or they were using etcher but have now moved to their own tool: Raspberry Pi Imager.
Thank you for your attention, I will continue my development over there with the pi folks.