Although the rear recovery environment worked initially, on a subsequent test restore, the recovery environment failed to load.
I have tried connecting the USB disk to a working system and using gparted to check the partition on the EFI Partition. Unfortunately, this didn’t make any difference.
I battled with the same boot partition issues. I now made hard partition copys of boot partition and copy it over when I want to do a custom install, as the process of creating a boot partition during a custom install is almost never accepted by the installer later on never mind how well you create and format it.
By making a partition copy with gparted, it always works off the bat as it is formatted correctly and has the exact correct size.
Saves me hours.