Just an update - Catalina seems to be a safe upgrade now.
I upgraded before but had issues, where the touchpad would often work but only via the legacy driver - which meant no 3 finger gestures. Scrolling worked with 2 fingers. Restarting multiple times fixed the issue temporarily but it was not a good experience. Probably 50% of the time the I2C touchpad kext would not be loaded correctly. As a result, I reinstalled Mojave and stuck with that ever since. I tried again last week and had a smooth upgrade experience: download the Catalina installer and run it!
A couple of observations:
1. The OS separates the system files into their own partition but it's easy to mount it. I would recommend Hackintool - as it allows you to both mount the system partition and rebuild the kext cache if needed. This is the main thing that put me off upgrading but actually it's been fine.
2. Filevault seems to be fine. Worked in Mojave and works in Cat just as well.
3. You must use APFS. With Mojave it was possible to initially install to an APFS drive and then clone that installation back to a drive formatted as HFS+ but this does not seem to be possible anymore. If you use APFS already then this won't be a concern for you. If there's a work-around please let me know so others can benefit
My Mojave install was on a drive formatted with HFS+ . My upgrade path was:
a) Format an external drive as APFS.
b) Use Carbon Copy Cloner to create a bootable backup of my Mojave install to the external, APFS drive. Run the clover installer to the external drive to make it bootable and copy the EFI folder to it.
c) Boot the cloned Mojave install from the external APFS drive.
d) Upgrade the Mojave install to Catalina via the 'Install Catalina' app (Check out Dosdude's patcher if you need a Catalina install image) on the external drive.
e) Boot the newly-upgraded Catalina install from the external drive.
f) Use disk utility to wipe the internal drive in my XPS and reformat as APFS.
g) Use Carbon Copy Cloner to clone the external drive to the newly-formatted internal drive.
h) Install clover and copy the EFI folder over.
You could possibly do a Time Machine backup, freshly install Catalina and then restore but I have not tried this myself.
4. Make sure that you use both the Kextupdater app and manually check the kext versions online - in particular the updates to the I2C touchpad kext seems to have greatly improved Catalina stability. As far as I am aware, you will need a forked version of BrcmPatchRAM. If this is not the case anymore please let me know. I have the forked KEXTS and they work fine for me:
https://github.com/acidanthera/BrcmPatchRAM/releases
I used the following patchram kexts: BrcmFirmwareData.kext, BrcmBluetoothInjector.kext and BrcmPatchRAM3.kext and this works fine. In Mojave I used BrcmPatchRAM2 and it still works in Catalina... But BrcmPatchRAM3 is apparently designed for Catalina. I haven't noticed any issues in upgrading to the BrcmPatchRAM3 kext, so I don't see a compelling reason not to change.
For reference I use the DW1830 WiFi card and with the above Bluetooth kexts. I don't see why the DW1560 would not also work equally as well.
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Everything works just as well as it did in Mojave. 32 bit apps are no longer supported but that's a Catalina issue that cannot be avoided and effects everyone. Only 1 app I use does not have a 64bit version but it is fairly resource-light and runs OK from a virtual machine.
Sorry for the wall of text - feel free to ask questions or point out any mistakes with what I wrote above so that I can make corrections.
Wishing you all a great week,
Benni.