Public bug reported:

Command line and options are identical between runs, except for the
hostname and LV (as passed to --raw)

# vmbuilder kvm ubuntu --hostname=$1 --raw=/dev/vg0/$1 -c
/etc/vmbuilder.cfg --debug -o --rootsize=8192 --swapsize=2048 --mem=512

# egrep -v "^$|^#" /etc/vmbuilder.cfg 
[DEFAULT]
[ubuntu]
mirror = http://ubuntu.catalyst.net.nz/ubuntu
security-mirror = http://ubuntu.catalyst.net.nz/ubuntu
suite = lucid
flavour = virtual
[kvm]
libvirt = qemu:///system
bridge = br0

Successful run excerpt:

2010-07-28 11:25:00,179 DEBUG   : ['rsync', '-a', 
'/tmp/tmpXcZ1l2/usr/lib/grub/x86_64-pc/', '/tmp/tmpXcZ1l2/boot/grub/']
2010-07-28 11:25:00,233 DEBUG   : ['chroot', '/tmp/tmpXcZ1l2', 'grub', 
'--device-map=/tmp/vmbuilder-grub/device.map', '--batch']
2010-07-28 11:25:00,234 DEBUG   : stdin was set and it was a string: root 
(hd0,0)
setup (hd0)
EOT
2010-07-28 11:25:01,239 DEBUG   : 
2010-07-28 11:25:01,239 DEBUG   :        [ Minimal BASH-like line editing is 
supported.   For
2010-07-28 11:25:01,240 DEBUG   :          the   first   word,  TAB  lists  
possible  command
2010-07-28 11:25:01,240 DEBUG   :          completions.  Anywhere else TAB 
lists the possible
2010-07-28 11:25:01,240 DEBUG   :          completions of a device/filename. ]
2010-07-28 11:25:01,241 DEBUG   : grub> root (hd0,0)
2010-07-28 11:25:01,241 DEBUG   : grub> setup (hd0)
2010-07-28 11:25:01,241 DEBUG   :  Checking if "/boot/grub/stage1" exists... yes
2010-07-28 11:25:01,241 DEBUG   :  Checking if "/boot/grub/stage2" exists... yes
2010-07-28 11:25:01,242 DEBUG   :  Checking if "/boot/grub/e2fs_stage1_5" 
exists... yes
2010-07-28 11:25:01,242 DEBUG   :  Running "embed /boot/grub/e2fs_stage1_5 
(hd0)"... failed (this is not fatal)
2010-07-28 11:25:01,242 DEBUG   :  Running "embed /boot/grub/e2fs_stage1_5 
(hd0,0)"... failed (this is not fatal)
2010-07-28 11:25:01,242 DEBUG   :  Running "install /boot/grub/stage1 (hd0) 
/boot/grub/stage2 p /boot/grub/menu.lst "... succeeded
2010-07-28 11:25:01,243 DEBUG   : Done.
2010-07-28 11:25:01,243 DEBUG   : grub> EOT
2010-07-28 11:25:01,244 DEBUG   : ['chroot', '/tmp/tmpXcZ1l2', 
'/usr/sbin/update-grub', '-y']
2010-07-28 11:25:01,381 INFO    : Searching for GRUB installation directory ... 
found: /boot/grub
2010-07-28 11:25:01,447 INFO    : Searching for default file ... Generating 
/boot/grub/default file and setting the default boot entry to 0
2010-07-28 11:25:01,449 INFO    : Searching for GRUB installation directory ... 
found: /boot/grub
2010-07-28 11:25:01,460 INFO    : Testing for an existing GRUB menu.lst file 
... 
2010-07-28 11:25:01,460 INFO    : 
2010-07-28 11:25:01,460 INFO    : Could not find /boot/grub/menu.lst file. 
2010-07-28 11:25:01,460 INFO    : Generating /boot/grub/menu.lst
2010-07-28 11:25:01,582 INFO    : Searching for splash image ... none found, 
skipping ...
2010-07-28 11:25:01,825 INFO    : grep: /boot/config*: No such file or directory
2010-07-28 11:25:01,966 INFO    : Updating /boot/grub/menu.lst ... done
2010-07-28 11:25:01,966 INFO    : 

Failed run:


2010-07-28 11:28:16,816 DEBUG   : ['rsync', '-a', 
'/tmp/tmpa5EOR4/usr/lib/grub/x86_64-pc/', '/tmp/tmpa5EOR4/boot/grub/']
2010-07-28 11:28:16,870 DEBUG   : ['chroot', '/tmp/tmpa5EOR4', 'grub', 
'--device-map=/tmp/vmbuilder-grub/device.map', '--batch']
2010-07-28 11:28:16,870 DEBUG   : stdin was set and it was a string: root 
(hd0,0)
setup (hd0)
EOT
2010-07-28 11:28:17,526 DEBUG   : 
2010-07-28 11:28:17,527 DEBUG   :        [ Minimal BASH-like line editing is 
supported.   For
2010-07-28 11:28:17,527 DEBUG   :          the   first   word,  TAB  lists  
possible  command
2010-07-28 11:28:17,527 DEBUG   :          completions.  Anywhere else TAB 
lists the possible
2010-07-28 11:28:17,528 DEBUG   :          completions of a device/filename. ]
2010-07-28 11:28:17,528 DEBUG   : grub> root (hd0,0)
2010-07-28 11:28:17,528 DEBUG   : grub> setup (hd0)
2010-07-28 11:28:17,528 DEBUG   :  Checking if "/boot/grub/stage1" exists... no
2010-07-28 11:28:17,529 DEBUG   :  Checking if "/grub/stage1" exists... no
2010-07-28 11:28:17,529 DEBUG   : 
2010-07-28 11:28:17,529 DEBUG   : Error 15: File not found
2010-07-28 11:28:17,530 DEBUG   : grub> EOT
2010-07-28 11:28:17,530 DEBUG   : ['chroot', '/tmp/tmpa5EOR4', 
'/usr/sbin/update-grub', '-y']
2010-07-28 11:28:17,664 INFO    : Searching for GRUB installation directory ... 
found: /boot/grub
2010-07-28 11:28:17,728 INFO    : Searching for default file ... Generating 
/boot/grub/default file and setting the default boot entry to 0
2010-07-28 11:28:17,731 INFO    : Searching for GRUB installation directory ... 
found: /boot/grub
2010-07-28 11:28:17,741 INFO    : Testing for an existing GRUB menu.lst file 
... 
2010-07-28 11:28:17,742 INFO    : 
2010-07-28 11:28:17,742 INFO    : Could not find /boot/grub/menu.lst file. 
2010-07-28 11:28:17,742 INFO    : Generating /boot/grub/menu.lst
2010-07-28 11:28:17,863 INFO    : Searching for splash image ... none found, 
skipping ...
2010-07-28 11:28:18,112 INFO    : grep: /boot/config*: No such file or directory
2010-07-28 11:28:18,255 INFO    : Updating /boot/grub/menu.lst ... done
2010-07-28 11:28:18,255 INFO    : 

Have tried different mirrors, {python,ubuntu}-vm-builder from the daily
ppa, not using tmpfs.

It works approximately half the time:

http://paste.ubuntu.com/469994/

** Affects: vm-builder (Ubuntu)
     Importance: Undecided
         Status: New

-- 
vmbuilder randomly fails to install grub
https://bugs.launchpad.net/bugs/610652
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