From 55466763bd08399a6a13768c7ebbd45d915eda7a Mon Sep 17 00:00:00 2001
From: GlassOnTin <GlassOnTin@users.noreply.github.com>
Date: Tue, 7 Apr 2026 21:03:26 +0100
Subject: [PATCH] Fix three LoRa blockers: stack overflow, warm reset, SPI
 mutex
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1. Stack overflow on first GPS fix: lxmf_build_message() and
   lxmf_build_announce() allocated ~1.2KB of local arrays on
   the stack (telemetry[128], payload[256], hashed_part[288],
   signed_part[320], signed_data[256]). Combined with LVGL,
   IMU, GPS, BLE this exceeded the 8KB task stack. Fixed by
   making these static — functions are never called concurrently.

2. hw_ready=0 after watchdog warm reset: device_init() required
   bt_ready which fails on warm reset (BLE hardware not fully
   reset). For T-Watch and T-Beam Supreme dev boards, skip the
   BLE requirement since we bypass signatures anyway.

3. Silent TX failure: shared_spi_mutex was removed from radio
   code but beacon_transmit() does SPI transactions that can
   collide with SD card access. Added mutex around the TX path
   in beacon_transmit() and diagnostic logging on TX failure.

Verified: T-Beam receives watch LXMF announce (↓191 B) after
GPS fix. No crash on first beacon. Interference at -74 dBm.
---
 Device.h           |  5 +++++
 LxmfBeacon.h       | 13 ++++++++-----
 RNode_Firmware.ino | 11 +++++++++--
 3 files changed, 22 insertions(+), 7 deletions(-)

diff --git a/Device.h b/Device.h
index 958811f..99061fb 100644
--- a/Device.h
+++ b/Device.h
@@ -220,7 +220,12 @@ bool device_firmware_ok() {
 
 #if MCU_VARIANT == MCU_ESP32 || MCU_VARIANT == MCU_NRF52
 bool device_init() {
+  #if BOARD_MODEL == BOARD_TWATCH_ULT || BOARD_MODEL == BOARD_TBEAM_S_V1
+    // Dev boards: proceed even if BLE not ready (warm reset race)
+    if (true) {
+  #else
   if (bt_ready) {
+  #endif
     #if MCU_VARIANT == MCU_ESP32
     for (uint8_t i=0; i<EEPROM_SIG_LEN; i++){dev_eeprom_signature[i]=EEPROM.read(eeprom_addr(ADDR_SIGNATURE+i));}
     mbedtls_md_context_t ctx;
diff --git a/LxmfBeacon.h b/LxmfBeacon.h
index b795a72..a6d6cfd 100644
--- a/LxmfBeacon.h
+++ b/LxmfBeacon.h
@@ -376,15 +376,20 @@ static int lxmf_build_message(uint8_t *out, size_t out_cap,
                                 double lat, double lon, double alt,
                                 double speed, double hdop,
                                 uint32_t timestamp, int bat_percent) {
+    // Static buffers to avoid stack overflow (~1KB saved)
+    // Safe because beacon functions are never called concurrently
+    static uint8_t telemetry[128];
+    static uint8_t payload[256];
+    static uint8_t hashed_part[256 + 32];
+    static uint8_t signed_part[256 + 32 + 32];
+
     // 1. Pack telemetry bytes
-    uint8_t telemetry[128];
     size_t telem_len = lxmf_pack_telemetry(telemetry, sizeof(telemetry),
                                             lat, lon, alt, speed, hdop,
                                             timestamp, bat_percent);
     if (telem_len == 0) return -1;
 
     // 2. Build msgpack payload: [timestamp, nil, nil, {0x02: telemetry}]
-    uint8_t payload[256];
     MsgpackWriter pw = { payload, 0, sizeof(payload) };
 
     pw.pack_fixarray(4);
@@ -407,7 +412,6 @@ static int lxmf_build_message(uint8_t *out, size_t out_cap,
 
     // 3. Compute signature
     //    hashed_part = dest_hash(16) + source_hash(16) + payload
-    uint8_t hashed_part[256 + 32];
     size_t hp_len = 16 + 16 + payload_len;
     if (hp_len > sizeof(hashed_part)) return -1;
     memcpy(hashed_part, dest_hash16, 16);
@@ -419,7 +423,6 @@ static int lxmf_build_message(uint8_t *out, size_t out_cap,
     sha256_once(hashed_part, hp_len, message_hash);
 
     //    signed_part = hashed_part + message_hash
-    uint8_t signed_part[256 + 32 + 32];
     size_t sp_len = hp_len + 32;
     if (sp_len > sizeof(signed_part)) return -1;
     memcpy(signed_part, hashed_part, hp_len);
@@ -537,7 +540,7 @@ static int lxmf_build_announce(uint8_t *out, size_t out_cap, const char *display
 
     // signature: Ed25519Sign(dest_hash + public_key + name_hash + random_hash + app_data)
     // signed_data = dest_hash(16) + public_key(64) + name_hash(10) + random_hash(10) + app_data
-    uint8_t signed_data[256];
+    static uint8_t signed_data[256];
     size_t sd_len = 0;
     memcpy(&signed_data[sd_len], lxmf_source_hash, 16); sd_len += 16;
     memcpy(&signed_data[sd_len], lxmf_x25519_pk, 32);   sd_len += 32;
diff --git a/RNode_Firmware.ino b/RNode_Firmware.ino
index 5cf8213..044cdf0 100644
--- a/RNode_Firmware.ino
+++ b/RNode_Firmware.ino
@@ -1017,12 +1017,19 @@ void beacon_transmit(uint16_t size) {
       diag_beacon_post_len = size;
     }
 
+    #if BOARD_MODEL == BOARD_TWATCH_ULT
+      if (shared_spi_mutex) xSemaphoreTake(shared_spi_mutex, portMAX_DELAY);
+    #endif
     LoRa->beginPacket();
     for (uint16_t i = 0; i < size; i++) {
       LoRa->write(tbuf[i]);
     }
-    if (!LoRa->endPacket()) {
-      led_indicate_error(5);
+    bool tx_ok = LoRa->endPacket();
+    #if BOARD_MODEL == BOARD_TWATCH_ULT
+      if (shared_spi_mutex) xSemaphoreGive(shared_spi_mutex);
+    #endif
+    if (!tx_ok) {
+      Serial.println("[beacon] TX failed");
     }
     stat_tx++;
     add_airtime(size);