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…as stripped) build_device_header() was slicing bytes [0:16] + [20:48], dropping the 4-byte prevAppVersion field and sending a 44-byte payload. The bootloader firmware-header struct includes prevAppVersion at offset 0x10, so it waited for 48 bytes and stalled. Fix: return raw[0:HEADER_SIZE] unchanged. DEVICE_HEADER_SIZE constant updated from 44 to HEADER_SIZE (48). Updated tests: replaced test_strips_prev_app_version_field with test_wire_header_is_full_48_byte_file_header and added test_prev_app_version_present_at_offset_16. Docs updated across FIRMWARE_FORMAT.md, PROTOCOL.md, ARCHITECTURE.md, USER_GUIDE.md, and firmware.py docstrings to reflect the 48-byte wire header. CHANGELOG.md notes that v1.2.0 requires the not-yet-released bootloader.
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changes implemented after secure bootloader updated with some fixes