chore(esp): drop esp-hal patches, bump to crates.io 1.1, add esp_app_desc!() and espflash v4
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@@ -33,142 +33,5 @@ Hardware impact: large stability gain on every board — the sx126x
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BUSY-race fix lands on every nRF/RP2040 board, and the sx127x IRQ-clear
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fixes unblock TBeam classic in particular. Hardware-verified on Wio
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Tracker L1 (sx126x): 20/20 clean-boot TX after the fix (vs ~50%
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before).
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---
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## Drop `[patch.crates-io]` + upgrade esp-hal / esp-rtos + add `esp_app_desc!()` + bump espflash to v4
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Single coordinated change that clears our last remaining dep-graph debt
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on the ESP boards. All four pieces are coupled, so they land together.
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### Why
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Today `Cargo.toml` overrides `esp-hal`, `esp-rtos`, `esp-backtrace`, and
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`esp-println` with a git pin to `esp-rs/esp-hal#main`. The note in that
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block explains the historical reason:
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> REVISIT: esp-rtos 0.2.0 on crates.io pins embassy-executor ^0.9. The
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> esp-rs/esp-hal main branch already supports 0.10. Remove these
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> patches once esp-rtos publishes a release with embassy-executor 0.10
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> support.
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**That condition is now met.** `esp-rtos 0.3.0` is published on crates.io
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and depends on `embassy-executor ^0.10` and `esp-hal ~1.1.0-rc.0` — exactly
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what our patches were pulling unofficially. Keeping the patches is no
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longer free: it blocks `espflash` v4, blocks `esp-bootloader-esp-idf`, and
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ties reproducible builds to whatever commit happens to be on
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`esp-rs/esp-hal#main`.
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The immediate trigger is `espflash` v4's required
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`esp_bootloader_esp_idf::esp_app_desc!()` check. `save-image` refuses any
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ESP binary that lacks the IDF app descriptor. The crate that provides the
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macro (`esp-bootloader-esp-idf`) uses the same `esp-rom-sys` native
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library as `esp-hal` — two copies of the same `links = "esp_rom_sys"` is
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a hard cargo error, so `esp-bootloader-esp-idf` must come from the _same
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source_ as `esp-hal`. Easiest way to guarantee that: both from crates.io,
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no patches.
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### What changes
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1. **`Cargo.toml`** — delete the entire `[patch.crates-io]` block and the
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preceding `REVISIT:` comment. Bump the four esp-rs deps to published
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versions:
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- `esp-hal = "1.0"` → `"1.1.0-rc.0"` (pre-release selector — see Gotchas)
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- `esp-rtos = "0.2"` → `"0.3"`
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- `esp-backtrace = "0.18"` → whatever matches esp-rtos 0.3 (check its deps)
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- `esp-println = "0.16"` → same
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Add a new optional dep + feature wiring for
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`esp-bootloader-esp-idf = "0.5"` with `defmt` feature, plus per-board
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chip feature (`esp-bootloader-esp-idf/esp32s3` for the S3 boards,
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`esp-bootloader-esp-idf/esp32` for LilyGo T-Beam classic).
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2. **`src/main.rs`** — inside the ESP-family branch of the existing
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`cfg_if!` block (around line 51), invoke the macro at module scope:
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```rust
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esp_bootloader_esp_idf::esp_app_desc!();
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```
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Zero runtime cost. Emits ~256 bytes in `.rodata_desc` with app
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metadata (name, version, build date) that the ESP-IDF 2nd-stage
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bootloader + `espflash save-image` look for.
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3. **`mise.toml`** — `"cargo:espflash" = "3"` → `"4"`. Drop the deferral
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comment on that line.
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4. **Possible API drift fixes** — esp-hal's pre-release versions
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occasionally rename or move items. Most likely touch points:
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- `src/board/esp32.rs`, `src/board/esp32s3.rs`
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- Any board file in `src/board/heltec_*.rs`, `lilygo_*.rs`,
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`elecrow_*.rs` that calls into esp-hal / esp-rtos init
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Run `just check-all` after steps 1–3 and patch up whatever surfaces.
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Don't guess — read the actual compiler errors.
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### How (step by step)
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1. `jj new -m "chore(esp): drop esp-hal patches, bump to published versions, add esp_app_desc!()"`
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2. Edit `Cargo.toml` — delete `[patch.crates-io]` + `REVISIT:` comment;
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bump the four versions; add `esp-bootloader-esp-idf` dep + feature
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wiring for each ESP board feature block.
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3. Edit `src/main.rs` — add `esp_bootloader_esp_idf::esp_app_desc!();`
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to the ESP branch of the top-level `cfg_if!`.
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4. Edit `mise.toml` — espflash `"3"` → `"4"`.
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5. `mise install` to pull espflash 4.x.
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6. `cargo update` to let the resolver pick a consistent tree with the
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new requirements.
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7. `just check-all` — expect some compilation errors from API drift on
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ESP boards. Fix them one at a time; consult the official examples
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in `esp-rs/esp-hal` if in doubt.
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8. `just build heltec_v3` (or any ESP board you have) — verify
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`espflash save-image` now succeeds end-to-end producing a valid
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`.bin`.
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9. Flash to real hardware if available. **The RAK4631 and Wio Tracker
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L1 (nRF52) boards should be untouched.**
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### Verification
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- `just check-all` clean on all 9 boards.
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- `just test` (host-side protocol tests) still green.
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- For each ESP board that has been physically validated before
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(Heltec V3, LilyGo T-Beam units): flash + confirm radio TX works
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end-to-end via ai-bot or a known peer.
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- RAK4631 + Wio Tracker L1 unchanged; re-check via `just check` on
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both, but no re-flash needed (they don't go through the ESP code
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path).
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### Gotchas
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- **Pre-release version selector**: `esp-hal = "1.1.0-rc.0"` by itself
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does NOT match pre-release versions in cargo's default semver rules.
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Use an exact pre-release like `"1.1.0-rc.0"`, `"~1.1.0-rc.0"` (only
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`1.1.0-rc.0`, `1.1.0-rc.1`, … with any patch), or `">=1.1.0-rc.0"`.
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`"1.1"` will NOT resolve to a pre-release.
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- **Two copies of `esp-rom-sys`**: the root cause of the first failed
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attempt at this task. If cargo errors with _"Only one package in the
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dependency graph may specify the same links value"_ for
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`esp_rom_sys`, it means `esp-hal` and `esp-bootloader-esp-idf` are
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being pulled from different sources (one crates.io, one git). Either
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both from crates.io (this task's plan) or both from the same git
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commit.
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- **`esp-bootloader-esp-idf` chip features**: the crate needs exactly
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one of `esp32 / esp32s3 / esp32c3 / esp32c6 / …` to be enabled.
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Without it, the build panics at its `build.rs`: _"Expected exactly
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one of the following features to be enabled: esp32, esp32c2, ..."_.
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Wire per-board the same way we wire `esp-hal/esp32s3` etc.
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- **Probe-less repro**: `mise install` after bumping espflash to "4"
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only installs mise's copy. If the user's global
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`~/.cargo/bin/espflash` is stale/different, it still wins on PATH.
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The justfile `set shell := ["mise", "exec", "--", "sh", "-c"]`
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prepends mise's paths but does NOT reorder `~/.cargo/bin` ahead of
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them. Either `cargo uninstall espflash` globally, or change the
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justfile recipes to call `$(mise which espflash)` explicitly.
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### Why not now
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Tried it alongside the RAK4631 bring-up in April 2026 and bounced off
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the `esp-rom-sys` two-copies problem. Backed out the attempt and left
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espflash pinned at v3 + the patches in place so the bring-up commit
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stayed atomic and shippable. This task is what's needed to unblock v4
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properly, but it deserves its own focused session — not as
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"while-I'm-here" scope on a board bring-up.
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before). LilyGo T-Beam classic (sx127x): TX confirmed working
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2026-04-30 on the post-esp-hal-1.1 build.
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