From 2f55877e75167d8050d3760de241c2d816c5d8ce Mon Sep 17 00:00:00 2001
From: ruv <ruv@ruv.net>
Date: Fri, 20 Mar 2026 18:40:17 -0400
Subject: [PATCH] ci: raise firmware binary size gate to 1100 KB for HTTP
 client stack

The swarm bridge (ADR-066) adds esp_http_client for Seed communication,
which pulls in the HTTP/TLS stack (~150 KB). Binary grew from ~978 KB to
~1077 KB. Raise the gate from 950 KB to 1100 KB. Still fits comfortably
in both 4MB (1856 KB OTA slot, 43% free) and 8MB flash variants.

Co-Authored-By: claude-flow <ruv@ruv.net>
---
 .github/workflows/firmware-ci.yml | 8 ++++----
 1 file changed, 4 insertions(+), 4 deletions(-)

diff --git a/.github/workflows/firmware-ci.yml b/.github/workflows/firmware-ci.yml
index e627e8ed..21ec9cfc 100644
--- a/.github/workflows/firmware-ci.yml
+++ b/.github/workflows/firmware-ci.yml
@@ -27,16 +27,16 @@ jobs:
           idf.py set-target esp32s3
           idf.py build
 
-      - name: Verify binary size (< 950 KB gate)
+      - name: Verify binary size (< 1100 KB gate)
         working-directory: firmware/esp32-csi-node
         run: |
           BIN=build/esp32-csi-node.bin
           SIZE=$(stat -c%s "$BIN")
-          MAX=$((950 * 1024))
+          MAX=$((1100 * 1024))
           echo "Binary size: $SIZE bytes ($(( SIZE / 1024 )) KB)"
-          echo "Size limit:  $MAX bytes (950 KB — includes Tier 3 WASM runtime)"
+          echo "Size limit:  $MAX bytes (1100 KB — includes WASM runtime + HTTP client for Seed swarm bridge)"
           if [ "$SIZE" -gt "$MAX" ]; then
-            echo "::error::Firmware binary exceeds 950 KB size gate ($SIZE > $MAX)"
+            echo "::error::Firmware binary exceeds 1100 KB size gate ($SIZE > $MAX)"
             exit 1
           fi
           echo "Binary size OK: $SIZE <= $MAX"