Firmware CI: esp32s3/8mb binary exceeds 1100 KB size gate by 144 bytes — failing on main since 2026-06-27

[ruvnet]

The Build firmware (esp32s3 / 8mb) job in the Firmware CI workflow has been failing on main since the 2026-06-27 run (commit fca5e6f):

##[error]Firmware binary exceeds 1100 KB size gate (1126544 > 1126400)

The byte count is identical on main and on unrelated PRs (e.g. #1332), so this is not caused by any in-flight change — the binary crossed the gate at or before fca5e6f and every Firmware CI run since fails at the size check, masking real regressions.

Options:

1. Trim ~150 bytes (e.g. log-string dedup, -Os on a compilation unit, drop an unused table)
2. Raise the gate to a defensible ceiling with headroom (e.g. 1152 KB) and document why
3. Make the gate warn at a soft limit and fail only at a hard limit

Either way, a green baseline on main should be restored so the gate means something again.

🤖 Generated with claude-flow

[ruvnet]

Fixed by PR #1355. Firmware CI now warns above 1100 KiB and fails at a documented 1152 KiB hard ceiling. The measured ESP32-S3 image is 1,126,624 bytes (1100.219 KiB); all S3 8 MB, S3 4 MB, and C6 matrix builds passed. Closing.