From 153292853fdf309f8858cdb34984476d1c8a9129 Mon Sep 17 00:00:00 2001
From: Dmitry Ilyin <6576495+widgetii@users.noreply.github.com>
Date: Fri, 23 Oct 2026 21:26:47 +0300
Subject: [PATCH 1/2] build: a fixed-slot package that no longer fits is
 skipped, not fatal

Boards on the split layout that still ship the fixed-slot package beside
it fail their whole build when the uImage outgrows 1983K or the rootfs
outgrows its 5 or 8 MiB slot. That is how hi3518ev300 lite broke the
nightly before #2656. On the 2026-10-22 nightly, the next ones are
close: the gk7205v200, gk7205v300 and gk7605v100 lite rootfs are 20K
short of 5120K, hi3516ev200 lite 24K and gk7202v300 lite 32K, growing
16-32K a month.

The fixed-slot package is the extra on these boards. A build whose
uImage or rootfs no longer fits its slot now ships the split package
alone, with a ::warning:: saying which sizes outgrew which slots. The
split package is checked and built exactly as before. Cameras on fixed
slots then upgrade to the split layout: sysupgrade falls back to the
-split package, and defib and the site's installer install it.

Tested on a gk7205v500 lite build's images (TARGET with its .config):
with the real sizes (uImage 1934K, rootfs 5044K) make repack builds both
packages as before; with the rootfs padded to 5130K it prints
"::warning::gk7205v500 lite: uImage 1934KB/1983KB, rootfs.squashfs
5130KB/5120KB outgrow the fixed slots; shipping the split package only"
and builds the -split package alone.
---
 Makefile | 23 +++++++++++++++++++++--
 1 file changed, 21 insertions(+), 2 deletions(-)

diff --git a/Makefile b/Makefile
index 3ddb6b6df..e4a0c0729 100644
--- a/Makefile
+++ b/Makefile
@@ -179,11 +179,16 @@ ifneq ($(wildcard $(TARGET)/images/firmware.bin),)
 # squashfs is: at the block right after the uImage is the split layout, at the
 # slot boundary fixed slots. A fixed-slot uImage ending in the slot's last block
 # would be both.
+#
+# The fixed-slot package is the extra: a build whose uImage or rootfs has
+# outgrown its slot ships the split package alone rather than failing, and
+# says so. Cameras on fixed slots then upgrade to the split layout, which
+# sysupgrade and defib install from the -split package.
 ifeq ($(BR2_OPENIPC_NOR_FIXED_PACKAGE),y)
 ifeq ($(BR2_OPENIPC_FLASH_SIZE),"8")
-	@$(call PREPARE_REPACK,uImage,1983,rootfs.squashfs,5120,nor)
+	@$(if $(call FIXED_SLOTS_FIT,5120),$(call PREPARE_REPACK,uImage,1983,rootfs.squashfs,5120,nor),$(call FIXED_SLOTS_SKIP,5120))
 else
-	@$(call PREPARE_REPACK,uImage,1983,rootfs.squashfs,8192,nor)
+	@$(if $(call FIXED_SLOTS_FIT,8192),$(call PREPARE_REPACK,uImage,1983,rootfs.squashfs,8192,nor),$(call FIXED_SLOTS_SKIP,8192))
 endif
 endif
 	@$(call CHECK_SIZE,firmware.bin,$(shell expr $(subst ",,$(BR2_OPENIPC_FLASH_SIZE)) \* 1024 - $$(( $(or $(BR2_OPENIPC_NOR_FIRMWARE_OFFSET),0x50000) / 1024 )) - 256))
@@ -368,6 +373,20 @@ define REPACK_FIRMWARE
 	rm -f $(TARGET)/images/*.md5sum
 endef
 
+# Whether uImage and rootfs.squashfs fit the fixed slots beside a split image:
+# the uImage under 1984K (see the repack target), the rootfs within $(1) KB,
+# both counted in whole KB as CHECK_SIZE counts them. "y" or empty.
+FIXED_SLOTS_FIT = $(shell k=$$(( $$(stat -c %s $(TARGET)/images/uImage 2>/dev/null || echo 0) / 1024 )); \
+	r=$$(( $$(stat -c %s $(TARGET)/images/rootfs.squashfs 2>/dev/null || echo 0) / 1024 )); \
+	[ $$k -gt 0 ] && [ $$k -le 1983 ] && [ $$r -gt 0 ] && [ $$r -le $(1) ] && echo y)
+
+define FIXED_SLOTS_SKIP
+	echo "::warning::$(BR2_OPENIPC_SOC_MODEL) $(BR2_OPENIPC_VARIANT): uImage" \
+		"$$(( $$(stat -c %s $(TARGET)/images/uImage) / 1024 ))KB/1983KB, rootfs.squashfs" \
+		"$$(( $$(stat -c %s $(TARGET)/images/rootfs.squashfs) / 1024 ))KB/$(1)KB outgrow the fixed slots;" \
+		"shipping the split package only"
+endef
+
 # The split NOR package: firmware.bin alone, under its own name so a sysupgrade
 # that predates the layout never sees it. Copies, as REPACK_NAND_FIT does.
 define REPACK_NOR_SPLIT

From d69c549063dcc6f0dac64912a58ac1e26a4ba11e Mon Sep 17 00:00:00 2001
From: Dmitry Ilyin <6576495+widgetii@users.noreply.github.com>
Date: Fri, 23 Oct 2026 22:07:42 +0300
Subject: [PATCH 2/2] build: the skip warning names only what outgrew its slot

From review: it named both images whenever either one did not fit. It now
lists the uImage, the rootfs or both, each with its size and slot.

Tested on a gk7205v500 lite build's images: rootfs padded to 5130K ->
'rootfs.squashfs 5130KB/5120KB outgrew the fixed slot'; uImage padded to
1990K -> 'uImage 1990KB/1983KB ...'; both -> both, comma-separated. The
-split package alone in each case.
---
 Makefile | 9 ++++++---
 1 file changed, 6 insertions(+), 3 deletions(-)

diff --git a/Makefile b/Makefile
index e4a0c0729..b2cd3714a 100644
--- a/Makefile
+++ b/Makefile
@@ -381,9 +381,12 @@ FIXED_SLOTS_FIT = $(shell k=$$(( $$(stat -c %s $(TARGET)/images/uImage 2>/dev/nu
 	[ $$k -gt 0 ] && [ $$k -le 1983 ] && [ $$r -gt 0 ] && [ $$r -le $(1) ] && echo y)
 
 define FIXED_SLOTS_SKIP
-	echo "::warning::$(BR2_OPENIPC_SOC_MODEL) $(BR2_OPENIPC_VARIANT): uImage" \
-		"$$(( $$(stat -c %s $(TARGET)/images/uImage) / 1024 ))KB/1983KB, rootfs.squashfs" \
-		"$$(( $$(stat -c %s $(TARGET)/images/rootfs.squashfs) / 1024 ))KB/$(1)KB outgrow the fixed slots;" \
+	k=$$(( $$(stat -c %s $(TARGET)/images/uImage) / 1024 )); \
+	r=$$(( $$(stat -c %s $(TARGET)/images/rootfs.squashfs) / 1024 )); \
+	over=; \
+	[ $$k -le 1983 ] || over="uImage $${k}KB/1983KB"; \
+	[ $$r -le $(1) ] || over="$${over:+$$over, }rootfs.squashfs $${r}KB/$(1)KB"; \
+	echo "::warning::$(BR2_OPENIPC_SOC_MODEL) $(BR2_OPENIPC_VARIANT): $$over outgrew the fixed slot;" \
 		"shipping the split package only"
 endef