Fit Mini Repeater with approved optional service cuts

docs/carrier_wave.md

@@ -4,6 +4,10 @@
 
 # Carrier-wave RF checks
 
+The constrained `wio-e5-mini_repeater` omits Morse and CW tools to fit its
+existing application region. Its packet radio and radio2 are unchanged.
+Other boards keep their existing carrier-tool support.
+
 ## TX-only Morse messages
 
 Morse TX mode keys an unmodulated carrier into dots and dashes. It does not send

docs/cli_commands.md

@@ -23,8 +23,10 @@ See [carrier-wave RF checks](carrier_wave.md) for `cw on [seconds]`,
 For keyed Morse TX, use `morse send TEST DE N0CALL` and `morse stop`.
 Defaults are **902.100 MHz and 25 WPM**; `set morse.freq <MHz>` and
 `set morse.wpm <1–60>` save separate frequency/speed settings.
-Small-flash STM32 production builds retain Morse TX but do not include Morse
+Small-flash STM32 Companion builds retain Morse TX but do not include Morse
 RX by default; listen/read/stats/clear return an unsupported-RX error there.
+The constrained `wio-e5-mini_repeater` omits Morse TX/RX and CW tools entirely;
+normal packet TX/RX and radio2 remain available.
 `get morse` shows status. See [TX-only Morse messages](carrier_wave.md#tx-only-morse-messages)
 for supported characters, limits, overlap checks and the temporary pause in
 packet reception. Nothing transmits automatically.
@@ -1423,6 +1425,11 @@ only `get mqtt.enabled`. WiFi modem power saving is a separate setting.
 
 **Search terms:** save logs, record received packets, RX logging, stored packet log.
 
+The constrained `wio-e5-mini_repeater` omits node-storage packet logging:
+`log start`, `log stop`, `log erase` and `log` are unavailable. Live
+USB/MQTT packet logging, `set usb.logging on|off` and statistics remain.
+Existing saved log files are not automatically deleted.
+
 **Usage:** `log start`
 
 ---

docs/management_reports.md

@@ -5,6 +5,10 @@
 # Management reports (MGR1/MGR2)
 
 Available on repeater (including observer), room-server and sensor firmware.
+Exception: the constrained `wio-e5-mini_repeater` omits management reporting
+and shared `data.tx` routing to fit its existing application region. Normal
+authenticated administration, statistics, live USB/MQTT logging and the
+host-service bridge remain available.
 Companions/terminal-chat nodes and KISS modems do not originate these reports.
 Off by default. A management password and explicit enable are both required.
 No radio settings, existing preferences layout, or OTA authorization policy is

docs/research/firmware_memory_budget.md

@@ -742,3 +742,53 @@ this experiment. No hardware was flashed, no failing image was published,
 and existing build outputs were not overwritten. Production compiler pins,
 features and capacity checks remain unchanged; the private source/tests,
 configs, verbose logs and linker maps were retained for further work.
+
+### Mini Repeater production recipe after file-logging approval
+
+After approval to also omit persistent packet-file logging, the three gates
+were adopted only for `wio-e5-mini_repeater`:
+`MESH_ENABLE_CARRIER_TOOLS=0`,
+`MESH_ENABLE_MANAGEMENT_REPORTING=0` and
+`MESH_ENABLE_PACKET_FILE_LOGGING=0`. All three default to 1 for other
+boards/roles. No compact numeric GET handler was adopted.
+
+The production recipe retains the existing GCC 14.2 package pin, adds the
+equivalent compact SHA-512/scalar/field implementations and unused Arduino
+timer-wrapper trims, and applies the five measured compiler flags to both
+compilation and the final LTO driver. The target-specific link hook is inert
+for other environments. Existing flash and runtime-RAM checks remain active.
+
+Canonical `build.sh build-firmware` links at release-version length
+(`v1.18.0.1-halo-keymind-cascade-dev`, Cascade, USA preset,
+`DISABLE_DEBUG=0`) pass:
+
+| Canonical target | Linked flash extent | App limit | Flash headroom | Runtime RAM available / required |
+| --- | ---: | ---: | ---: | ---: |
+| Wio-E5 Mini Repeater | 245,376 | 245,760 | 384 | 44,560 / 32,288 |
+| Wio-E5 Mini USB Companion regression control | 229,096 | 229,376 | 280 | 24,256 / 17,408 |
+
+These are conservative complete flash extents, not PlatformIO's selected
+section sums. The Repeater still reserves its original 16 KiB filesystem,
+50 neighbours, radio2, authenticated administration, host-service bridge and
+runtime-controlled live USB packet logging for an external MQTT bridge.
+The Companion keeps its 32 KiB filesystem and existing features. GCC 15 is
+not required and no toolchain upgrade was adopted.
+
+The omitted file feature is only node-local `/packet_log` capture and
+`log start|stop|erase` / local `log` dumping. Live raw RX/TX framing, USB
+logging controls, statistics, watchdogs and bridge callbacks remain. Old
+saved log files are left untouched rather than automatically erased.
+Management-disabled routing fails closed and retains shared initialization
+needed by independently enabled Fleet/beacon features.
+
+Focused coverage now runs in CI alongside an exact cable-only Mini Repeater
+build at release-version length. It covers the feature gates, default-on
+behavior, raw logging and backpressure under all eight flag combinations,
+shared cooperative serial output, crypto equivalence, CLI permissions and
+Morse/radio recovery. Production-source and host-test review found no blocker.
+
+Both flash margins are narrow: future changes must re-link, not assume these
+images fit. These results qualify linked capacity and host behavior, not
+physical USB/RF/MQTT integration, board boot/sleep or a sustained-load soak.
+The Mini Repeater remains cable-only (`--allow-no-ota`); no hardware was
+flashed, no release was published and existing outputs were not overwritten.