Fix full firmware matrix capacity failures

build.sh

@@ -2142,7 +2142,7 @@ run_logging_matrix_build_targets() {
   fi
 
   if [ ${#constrained_logging_targets[@]} -gt 0 ]; then
-    echo "Building ${#constrained_logging_targets[@]} 224KB STM32 repeater target(s) with packet logging on and MESH_DEBUG off to fit flash: Tiny_Relay_repeater, RAK_3x72_repeater, wio-e5_repeater."
+    echo "Building ${#constrained_logging_targets[@]} size-constrained STM32 target(s) with packet logging on and MESH_DEBUG off to fit flash."
     MESHDEBUG_OVERRIDE="off"
     PACKET_LOGGING_OVERRIDE="on"
     MQTT_BRIDGE_OVERRIDE="off"

platformio.ini

@@ -195,6 +195,15 @@ lib_deps =
   adafruit/Adafruit BME680 Library @ ^2.0.4
   adafruit/Adafruit BMP085 Library @ ^1.2.4
 
+; The VL53L0X and BME680/BSEC stacks prevent some nRF52840 repeater images from fitting
+; the safe in-place LoRa OTA window. Space-constrained targets retain GPS, the other
+; environmental sensors, and board-native telemetry while omitting these optional sensors.
+[nrf52_ota_sensor_trim]
+build_flags =
+  -UENV_INCLUDE_VL53L0X
+  -UENV_INCLUDE_BME680
+  -UENV_INCLUDE_BME680_BSEC
+
 ; ----------------- TESTING ---------------------
 
 [env:native]

variants/gat562_30s_mesh_kit/platformio.ini

@@ -36,6 +36,7 @@ lib_deps =
 extends = GAT562_30S_Mesh_Kit
 build_flags =
   ${GAT562_30S_Mesh_Kit.build_flags}
+  ${nrf52_ota_sensor_trim.build_flags}
   -D DISPLAY_CLASS=SSD1306Display
   -D ADVERT_NAME='"GAT562 Repeater"'
   -D ADVERT_LAT=0.0

variants/heltec_t114/platformio.ini

@@ -164,6 +164,7 @@ build_src_filter = ${Heltec_t114_with_display.build_src_filter}
 
 build_flags =
   ${Heltec_t114_with_display.build_flags}
+  ${nrf52_ota_sensor_trim.build_flags}
   -D ADVERT_NAME='"Heltec_T114 Repeater"'
   -D ADVERT_LAT=0.0
   -D ADVERT_LON=0.0

variants/lilygo_tlora_v2_1/dual_ota_1984k.csv

@@ -0,0 +1,6 @@
+# Name,   Type, SubType, Offset,  Size,     Flags
+nvs,      data, nvs,     0x9000,  0x5000,
+otadata,  data, ota,     0xe000,  0x2000,
+app0,     app,  ota_0,   0x10000, 0x1F0000,
+app1,     app,  ota_1,   0x200000,0x1F0000,
+spiffs,   data, spiffs,  0x3F0000,0x10000,

variants/lilygo_tlora_v2_1/platformio.ini

@@ -147,6 +147,8 @@ lib_deps =
 ; Set extra slots to "none" (e.g. set mqtt2.preset none). See MQTT_IMPLEMENTATION.md.
 [env:LilyGo_TLora_V2_1_1_6_repeater_observer_mqtt]
 extends = LilyGo_TLora_V2_1_1_6_core
+; Preserve two OTA app slots while reclaiming coredump/half of SPIFFS for the MQTT repeater image.
+board_build.partitions = variants/lilygo_tlora_v2_1/dual_ota_1984k.csv
 extra_scripts =
   ${esp32_base.extra_scripts}
   pre:scripts/generate_cert_bundle.py

variants/rak3x72/platformio.ini

@@ -16,8 +16,10 @@ build_src_filter = ${stm32_base.build_src_filter}
 
 [env:RAK_3x72_repeater]
 extends = rak3x72
+board_upload.maximum_size = 245760 ; 240 KiB app, 16 KiB LittleFS
 build_flags = ${rak3x72.build_flags}
   -flto
+  -D LFS_FLASH_TOTAL_SIZE=16384
   -D ADVERT_NAME='"RAK3x72 Repeater"'
   -D ADMIN_PASSWORD='"password"'
   -D MAX_NEIGHBOURS=50

variants/rak4631/platformio.ini

@@ -109,6 +109,7 @@ lib_deps =
 extends = rak4631
 build_flags =
   ${rak4631.build_flags}
+  ${nrf52_ota_sensor_trim.build_flags}
   -D DISPLAY_CLASS=SSD1306Display
   -D ADVERT_NAME='"RS232 Bridge"'
   -D ADVERT_LAT=0.0
@@ -132,6 +133,7 @@ build_src_filter = ${rak4631.build_src_filter}
 extends = rak4631
 build_flags =
   ${rak4631.build_flags}
+  ${nrf52_ota_sensor_trim.build_flags}
   -D DISPLAY_CLASS=SSD1306Display
   -D ADVERT_NAME='"RS232 Bridge"'
   -D ADVERT_LAT=0.0

variants/tiny_relay/platformio.ini

@@ -17,8 +17,10 @@ build_src_filter = ${stm32_base.build_src_filter}
 
 [env:Tiny_Relay_repeater]
 extends = Tiny_Relay
+board_upload.maximum_size = 245760 ; 240 KiB app, 16 KiB LittleFS
 build_flags = ${Tiny_Relay.build_flags}
-  -flto ; this 224 KiB target otherwise has no room for current repeater safety features
+  -flto ; retain headroom for current repeater safety features
+  -D LFS_FLASH_TOTAL_SIZE=16384
   -D ADVERT_NAME='"tiny_relay Repeater"'
   -D ADVERT_LAT=0.0
   -D ADVERT_LON=0.0

variants/wio-e5-dev/platformio.ini

@@ -17,8 +17,10 @@ build_src_filter = ${stm32_base.build_src_filter}
 
 [env:wio-e5_repeater]
 extends = lora_e5
+board_upload.maximum_size = 245760 ; 240 KiB app, 16 KiB LittleFS
 build_flags = ${lora_e5.build_flags}
   -flto
+  -D LFS_FLASH_TOTAL_SIZE=16384
   -D LORA_TX_POWER=22
   -D ADVERT_NAME='"WIO-E5 Repeater"'
   -D ADMIN_PASSWORD='"password"'
@@ -28,8 +30,10 @@ build_src_filter = ${lora_e5.build_src_filter}
 
 [env:wio-e5-repeater_bridge_rs232]
 extends = lora_e5
+board_upload.maximum_size = 245760 ; 240 KiB app, 16 KiB LittleFS
 build_flags = ${lora_e5.build_flags}
   -flto
+  -D LFS_FLASH_TOTAL_SIZE=16384
   -D MESH_ENABLE_RECENT_REPEATERS=1
   -D LORA_TX_POWER=22
   -D ADVERT_NAME='"WIO-E5 Repeater"'

variants/wio-e5-mini/platformio.ini

@@ -19,8 +19,10 @@ lib_deps = ${stm32_base.lib_deps}
 
 [env:wio-e5-mini_repeater]
 extends = lora_e5_mini
+board_upload.maximum_size = 245760 ; 240 KiB app, 16 KiB LittleFS
 build_flags = ${lora_e5_mini.build_flags}
   -flto
+  -D LFS_FLASH_TOTAL_SIZE=16384
   -D MESH_ENABLE_RECENT_REPEATERS=1
   -D LORA_TX_POWER=22
   -D ADVERT_NAME='"wio-e5-mini Repeater"'