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All three matrix entries shared size_limit_kb=1152 regardless of their actual ota_0 partition size, so the gate was meaningless for the two variants whose slots are far larger than 1152 KB and correspondingly loose for none of them in the way that mattered: it does not track what "leaves headroom for OTA" actually means per partition table. Set each variant's limit to ~80% of its own ota_0 slot and the warn threshold to ~90% of the new limit: esp32s3 / 8mb (partitions_display.csv, ota_0 0x200000 = 2048 KB) -> 1638 / 1474 esp32s3 / 4mb (partitions_4mb.csv, ota_0 0x1D0000 = 1856 KB) -> 1484 / 1335 esp32c6 / c6-4mb (partitions_4mb.csv, same table as esp32s3/4mb) -> 1484 / 1335 Verified each variant's partition_table_name against the matrix before computing its number rather than assuming; c6-4mb shares partitions_4mb.csv with esp32s3/4mb, not a distinct C6 table. Co-Authored-By: claude-flow <ruv@ruv.net> Claude-Session: https://claude.ai/code/session_01PVWMiHQifoYXL7uL3bphrZ
…zing main had independently bumped the 8mb variant's size_limit_kb from 1152 to 1200 (dbaa3c7) as a stopgap while 4mb/c6-4mb stayed at 1152, conflicting with this branch's bb22a8c fix that sizes every variant to ~80%/90% of its own ota_0 OTA slot. Resolved by keeping the slot-based numbers (8mb 1638/1474 KB; 4mb and c6-4mb 1484/1335 KB), re-derived directly from partitions_display.csv (ota_0 0x200000 = 2048 KiB) and partitions_4mb.csv (ota_0 0x1D0000 = 1856 KiB) rather than trusting the prior commit's math, which the CSVs happen to confirm exactly. Co-Authored-By: claude-flow <ruv@ruv.net>
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firmware-ci.ymlappliessize_limit_kb: 1152to all three build variants, whoseota_0slots are very different sizes:New limits are ~80% of each slot, with
size_warn_kbat ~90% of the limit, so real headroom is preserved rather than removed.The current gate is not a hardware limit.
mainbuilds the 8MB variant at 1,171,248 bytes: 99.3% of the 1152 KB gate, but only 56% of the 2 MB partition it actually flashes into. Any feature addition trips a ceiling roughly half the size of the available space, which is what happened on #1827.No other workflow logic is changed.
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https://claude.ai/code/session_01PVWMiHQifoYXL7uL3bphrZ