diff --git a/.github/scripts/check-pg-versions.sh b/.github/scripts/check-pg-versions.sh
deleted file mode 100755
index 9a15be8913a..00000000000
--- a/.github/scripts/check-pg-versions.sh
+++ /dev/null
@@ -1,186 +0,0 @@
-#!/bin/bash
-#
-# Check if parameter group struct modifications include version increments
-# This prevents settings corruption when struct layout changes without version bump
-#
-# Exit codes:
-#   0 - No issues found
-#   1 - Potential issues detected (will post comment)
-#   2 - Script error
-
-set -euo pipefail
-
-# Output file for issues found
-ISSUES_FILE=$(mktemp)
-trap "rm -f $ISSUES_FILE" EXIT
-
-# Color output for local testing
-if [ -t 1 ]; then
-    RED='\033[0;31m'
-    GREEN='\033[0;32m'
-    YELLOW='\033[1;33m'
-    NC='\033[0m' # No Color
-else
-    RED=''
-    GREEN=''
-    YELLOW=''
-    NC=''
-fi
-
-echo "🔍 Checking for Parameter Group version updates..."
-
-# Get base and head commits
-BASE_REF=${GITHUB_BASE_REF:-}
-HEAD_REF=${GITHUB_HEAD_REF:-}
-
-if [ -z "$BASE_REF" ] || [ -z "$HEAD_REF" ]; then
-    echo "⚠️  Warning: Not running in GitHub Actions PR context"
-    echo "Using git diff against HEAD~1 for local testing"
-    BASE_COMMIT="HEAD~1"
-    HEAD_COMMIT="HEAD"
-else
-    BASE_COMMIT="origin/$BASE_REF"
-    HEAD_COMMIT="HEAD"
-fi
-
-# Get list of changed files
-CHANGED_FILES=$(git diff --name-only $BASE_COMMIT..$HEAD_COMMIT | grep -E '\.(c|h)$' || true)
-
-if [ -z "$CHANGED_FILES" ]; then
-    echo "✅ No C/H files changed"
-    exit 0
-fi
-
-echo "📁 Changed files:"
-echo "$CHANGED_FILES" | sed 's/^/  /'
-
-# Function to extract PG info from a file
-check_file_for_pg_changes() {
-    local file=$1
-    local diff_output=$(git diff $BASE_COMMIT..$HEAD_COMMIT -- "$file")
-
-    # Check if file contains PG_REGISTER (in either old or new version)
-    if ! echo "$diff_output" | grep -q "PG_REGISTER"; then
-        return 0
-    fi
-
-    echo "  🔎 Checking $file (contains PG_REGISTER)"
-
-    # Extract all PG_REGISTER lines from the diff (both old and new)
-    local pg_registers=$(echo "$diff_output" | grep -E "^[-+].*PG_REGISTER" || true)
-
-    if [ -z "$pg_registers" ]; then
-        # PG_REGISTER exists but wasn't changed
-        # Still need to check if the struct changed
-        pg_registers=$(git show $HEAD_COMMIT:"$file" | grep "PG_REGISTER" || true)
-    fi
-
-    # Process each PG registration
-    while IFS= read -r pg_line; do
-        [ -z "$pg_line" ] && continue
-
-        # Extract struct name and version
-        # Pattern: PG_REGISTER.*\((\w+),\s*(\w+),\s*PG_\w+,\s*(\d+)\)
-        if [[ $pg_line =~ PG_REGISTER[^(]*\(([^,]+),([^,]+),([^,]+),([^)]+)\) ]]; then
-            local struct_type="${BASH_REMATCH[1]}"
-            local pg_name="${BASH_REMATCH[2]}"
-            local pg_id="${BASH_REMATCH[3]}"
-            local version="${BASH_REMATCH[4]}"
-
-            # Clean up whitespace
-            struct_type=$(echo "$struct_type" | xargs)
-            version=$(echo "$version" | xargs)
-
-            echo "    📋 Found: $struct_type (version $version)"
-
-            # Check if this struct's typedef was modified
-            local struct_pattern="typedef struct ${struct_type%_t}_s"
-            # Isolate struct body from diff, remove comments and empty lines, then check for remaining changes
-            local struct_body_diff=$(echo "$diff_output" | sed -n "/${struct_pattern}/,/\}.*${struct_type};/p")
-
-            # If struct not found in current file, check corresponding .h or .c file
-            if [ -z "$struct_body_diff" ]; then
-                local companion_file=""
-                if [[ "$file" == *.c ]]; then
-                    companion_file="${file%.c}.h"
-                elif [[ "$file" == *.h ]]; then
-                    companion_file="${file%.h}.c"
-                fi
-
-                if [ -n "$companion_file" ] && git diff --name-only $BASE_COMMIT..$HEAD_COMMIT | grep -q "^${companion_file}$"; then
-                    echo "    🔍 Struct not in $file, checking $companion_file"
-                    local companion_diff=$(git diff $BASE_COMMIT..$HEAD_COMMIT -- "$companion_file")
-                    struct_body_diff=$(echo "$companion_diff" | sed -n "/${struct_pattern}/,/\}.*${struct_type};/p")
-                fi
-            fi
-
-            local struct_changes=$(echo "$struct_body_diff" | grep -E "^[-+]" \
-                | grep -v -E "^[-+]\s*(typedef struct|}|//|\*)" \
-                | sed -E 's://.*$::' \
-                | sed -E 's:/\*.*\*/::' \
-                | tr -d '[:space:]')
-
-            if [ -n "$struct_changes" ]; then
-                echo "    ⚠️  Struct definition modified"
-
-                # Check if version was incremented in this diff
-                local old_version=$(echo "$diff_output" | grep "^-.*PG_REGISTER.*$struct_type" | grep -oP ',\s*\K\d+(?=\s*\))' || echo "")
-                local new_version=$(echo "$diff_output" | grep "^+.*PG_REGISTER.*$struct_type" | grep -oP ',\s*\K\d+(?=\s*\))' || echo "")
-
-                if [ -n "$old_version" ] && [ -n "$new_version" ]; then
-                    if [ "$new_version" -le "$old_version" ]; then
-                        echo "    ❌ Version NOT incremented ($old_version → $new_version)"
-
-                        # Find line number of PG_REGISTER
-                        local line_num=$(git show $HEAD_COMMIT:"$file" | grep -n "PG_REGISTER.*$struct_type" | cut -d: -f1 | head -1)
-
-                        # Add to issues list
-                        cat >> $ISSUES_FILE << EOF
-### \`$struct_type\` ($file:$line_num)
-- **Struct modified:** Field changes detected
-- **Version status:** ❌ Not incremented (version $version)
-- **Recommendation:** Review changes and increment version if needed
-
-EOF
-                    else
-                        echo "    ✅ Version incremented ($old_version → $new_version)"
-                    fi
-                elif [ -z "$old_version" ] || [ -z "$new_version" ]; then
-                    # Couldn't determine version change, but struct was modified
-                    echo "    ⚠️  Could not determine if version was incremented"
-
-                    local line_num=$(git show $HEAD_COMMIT:"$file" | grep -n "PG_REGISTER.*$struct_type" | cut -d: -f1 | head -1)
-
-                    cat >> $ISSUES_FILE << EOF
-### \`$struct_type\` ($file:$line_num)
-- **Struct modified:** Field changes detected
-- **Version status:** ⚠️  Unable to verify version increment
-- **Current version:** $version
-- **Recommendation:** Verify version was incremented if struct layout changed
-
-EOF
-                fi
-            else
-                echo "    ✅ Struct unchanged"
-            fi
-        fi
-    done <<< "$pg_registers"
-}
-
-# Check each changed file
-while IFS= read -r file; do
-    check_file_for_pg_changes "$file"
-done <<< "$CHANGED_FILES"
-
-# Check if any issues were found
-if [ -s $ISSUES_FILE ]; then
-    echo ""
-    echo "${YELLOW}⚠️  Potential PG version issues detected${NC}"
-    echo "Output saved to: $ISSUES_FILE"
-    cat $ISSUES_FILE
-    exit 1
-else
-    echo ""
-    echo "${GREEN}✅ No PG version issues detected${NC}"
-    exit 0
-fi
diff --git a/.github/workflows/pg-version-check.yml b/.github/workflows/pg-version-check.yml
deleted file mode 100644
index d9d8c289930..00000000000
--- a/.github/workflows/pg-version-check.yml
+++ /dev/null
@@ -1,128 +0,0 @@
-name: Parameter Group Version Check
-
-on:
-  pull_request:
-    types: [opened, synchronize, reopened]
-    branches:
-      - maintenance-9.x
-      - maintenance-10.x
-    paths:
-      - 'src/**/*.c'
-      - 'src/**/*.h'
-
-jobs:
-  check-pg-versions:
-    runs-on: ubuntu-latest
-    permissions:
-      contents: read
-      pull-requests: write
-
-    steps:
-      - name: Checkout PR code
-        uses: actions/checkout@v4
-        with:
-          fetch-depth: 0  # Need full history to compare with base branch
-
-      - name: Fetch base branch
-        run: |
-          git fetch origin ${{ github.base_ref }}:refs/remotes/origin/${{ github.base_ref }}
-
-      - name: Run PG version check script
-        id: pg_check
-        run: |
-          set +e  # Don't fail the workflow, just capture exit code
-          # Run script and capture output. Exit code 1 is expected for issues.
-          # The output is captured and encoded to be passed between steps.
-          output=$(bash .github/scripts/check-pg-versions.sh 2>&1)
-          exit_code=$?
-          echo "exit_code=${exit_code}" >> $GITHUB_OUTPUT
-          echo "output<<EOF" >> $GITHUB_OUTPUT
-          echo "$output" >> $GITHUB_OUTPUT
-          echo "EOF" >> $GITHUB_OUTPUT
-        env:
-          GITHUB_BASE_REF: ${{ github.base_ref }}
-          GITHUB_HEAD_REF: ${{ github.head_ref }}
-
-      - name: Post comment if issues found
-        if: steps.pg_check.outputs.exit_code == '1'
-        uses: actions/github-script@v7
-        with:
-          script: |
-            // Use the captured output from the previous step
-            const output = '${{ steps.pg_check.outputs.output }}';
-            let issuesContent = '';
-
-            try {
-              // Extract issues from output (everything after the warning line)
-              const lines = output.split('\n');
-              let capturing = false;
-              let issues = [];
-
-              for (const line of lines) {
-                if (line.includes('###')) {
-                  capturing = true;
-                }
-                if (capturing) {
-                  issues.push(line);
-                }
-              }
-
-              issuesContent = issues.join('\n');
-            } catch (err) {
-              console.log('Error capturing issues:', err);
-              issuesContent = '*Unable to extract detailed issues*';
-            }
-
-            const commentBody = '## ⚠️ Parameter Group Version Check\n\n' +
-              'The following parameter groups may need version increments:\n\n' +
-              issuesContent + '\n\n' +
-              '**Why this matters:**\n' +
-              'Modifying PG struct fields without incrementing the version can cause settings corruption when users flash new firmware. The `pgLoad()` function validates versions and will use defaults if there\'s a mismatch, preventing corruption.\n\n' +
-              '**When to increment the version:**\n' +
-              '- ✅ Adding/removing fields\n' +
-              '- ✅ Changing field types or sizes\n' +
-              '- ✅ Reordering fields\n' +
-              '- ✅ Adding/removing packing attributes\n' +
-              '- ❌ Only changing default values in `PG_RESET_TEMPLATE`\n' +
-              '- ❌ Only changing comments\n\n' +
-              '**Reference:**\n' +
-              '- [Parameter Group Documentation](../docs/development/parameter_groups/)\n' +
-              '- Example: [PR #11236](https://github.com/iNavFlight/inav/pull/11236) (field removal requiring version increment)\n\n' +
-              '---\n' +
-              '*This is an automated check. False positives are possible. If you believe the version increment is not needed, please explain in a comment.*';
-
-            try {
-              // Check if we already commented
-              const { data: comments } = await github.rest.issues.listComments({
-                owner: context.repo.owner,
-                repo: context.repo.repo,
-                issue_number: context.issue.number,
-              });
-
-              const botComment = comments.find(comment =>
-                comment.user.login === 'github-actions[bot]' &&
-                comment.body.includes('Parameter Group Version Check')
-              );
-
-              if (botComment) {
-                // Update existing comment
-                await github.rest.issues.updateComment({
-                  owner: context.repo.owner,
-                  repo: context.repo.repo,
-                  comment_id: botComment.id,
-                  body: commentBody
-                });
-                console.log('Updated existing PG version check comment');
-              } else {
-                // Post new comment
-                await github.rest.issues.createComment({
-                  owner: context.repo.owner,
-                  repo: context.repo.repo,
-                  issue_number: context.issue.number,
-                  body: commentBody
-                });
-                console.log('Posted new PG version check comment');
-              }
-            } catch (err) {
-              core.setFailed(`Failed to post comment: ${err}`);
-            }
diff --git a/cmake/check-pg-struct-sizes.sh b/cmake/check-pg-struct-sizes.sh
new file mode 100755
index 00000000000..fcbbbcac0ed
--- /dev/null
+++ b/cmake/check-pg-struct-sizes.sh
@@ -0,0 +1,133 @@
+#!/bin/bash
+#
+# Check PG struct sizes against database
+# Fails build if size changed but PG version wasn't incremented
+#
+# Usage: check-pg-struct-sizes.sh <elf_file>
+#
+
+set -euo pipefail
+
+ELF_FILE=$1
+SCRIPT_DIR=$(dirname "$0")
+DB_FILE="$SCRIPT_DIR/pg_struct_sizes.db"
+
+if [ ! -f "$ELF_FILE" ]; then
+    echo "Error: ELF file not found: $ELF_FILE" >&2
+    exit 1
+fi
+
+if [ ! -f "$DB_FILE" ]; then
+    echo "⚠️  Warning: PG struct sizes database not found: $DB_FILE" >&2
+    echo "   Run: $SCRIPT_DIR/extract-pg-sizes-nm.sh $ELF_FILE > $DB_FILE" >&2
+    echo "   Skipping validation." >&2
+    exit 0
+fi
+
+echo "🔍 Checking PG struct sizes against database..."
+
+# Extract current sizes
+TEMP_CURRENT=$(mktemp)
+"$SCRIPT_DIR/extract-pg-sizes-nm.sh" "$ELF_FILE" 2>/dev/null > "$TEMP_CURRENT"
+
+# Function to get PG version from source code
+get_pg_version() {
+    local struct_type=$1
+
+    # Remove _t suffix to get config name
+    # e.g., blackboxConfig_t -> blackboxConfig
+    local config_name="${struct_type%_t}"
+
+    # Search for PG_REGISTER in source files
+    # Format: PG_REGISTER_WITH_RESET_TEMPLATE(type, name, pgn, version)
+    #     or: PG_REGISTER_WITH_RESET_FN(type, name, pgn, version)
+    #     or: PG_REGISTER(type, name, pgn, version)
+    local version=$(grep -rh "PG_REGISTER.*$config_name" src/main --include="*.c" 2>/dev/null | \
+        grep -oP 'PG_REGISTER[^(]*\([^,]+,[^,]+,[^,]+,\s*\K\d+' | head -1)
+
+    echo "$version"
+}
+
+FAILED=0
+ISSUES=""
+UPDATED=""
+
+# Check each struct in current binary
+while read -r struct_type current_size; do
+    [ -z "$struct_type" ] && continue
+
+    # Look up in database
+    db_entry=$(grep "^$struct_type " "$DB_FILE" 2>/dev/null || echo "")
+
+    if [ -z "$db_entry" ]; then
+        # New struct not in database - add it automatically
+        current_version=$(get_pg_version "$struct_type")
+
+        if [ -z "$current_version" ]; then
+            echo "  ⚠️  Warning: Cannot find PG version for new struct $struct_type" >&2
+            echo "  ℹ️  New: $struct_type (${current_size}B) - skipping (no PG_REGISTER found)"
+            continue
+        fi
+
+        echo "  ➕ New: $struct_type (${current_size}B, v$current_version)"
+
+        # Add to database
+        printf "%-30s %3s %s\n" "$struct_type" "$current_size" "$current_version" >> "$DB_FILE"
+        UPDATED="$UPDATED\n  • $struct_type: NEW (${current_size}B, v$current_version)"
+        continue
+    fi
+
+    db_size=$(echo "$db_entry" | awk '{print $2}')
+    db_version=$(echo "$db_entry" | awk '{print $3}')
+
+    if [ "$current_size" != "$db_size" ]; then
+        # Size changed - check if version was incremented
+        current_version=$(get_pg_version "$struct_type")
+
+        if [ -z "$current_version" ]; then
+            echo "  ⚠️  Warning: Cannot find PG version for $struct_type" >&2
+            continue
+        fi
+
+        if [ "$current_version" -le "$db_version" ]; then
+            # SIZE CHANGED BUT VERSION NOT INCREMENTED - FAIL BUILD
+            echo "  ❌ $struct_type: size changed ${db_size}B → ${current_size}B but version not incremented (still v$current_version)"
+            ISSUES="$ISSUES\n  • $struct_type: ${db_size}B → ${current_size}B (version $current_version should be $((current_version + 1)))"
+            FAILED=1
+        else
+            # Version was incremented - this is valid, update database
+            echo "  ✅ $struct_type: size changed ${db_size}B → ${current_size}B with version increment v$db_version → v$current_version"
+
+            # Update database entry with new size and version
+            sed -i "s/^$struct_type  *[0-9]* *[0-9]*$/$(printf "%-30s %3s %s" "$struct_type" "$current_size" "$current_version")/" "$DB_FILE"
+            UPDATED="$UPDATED\n  • $struct_type: ${db_size}B → ${current_size}B (v$db_version → v$current_version)"
+        fi
+    else
+        # Size unchanged
+        echo "  ✓ $struct_type (${current_size}B)"
+    fi
+done < "$TEMP_CURRENT"
+
+rm -f "$TEMP_CURRENT"
+
+if [ $FAILED -eq 1 ]; then
+    echo ""
+    echo "❌ PG STRUCT SIZE VALIDATION FAILED"
+    echo ""
+    echo "The following structs changed size without version increments:"
+    echo -e "$ISSUES"
+    echo ""
+    echo "Fix: Increment PG version in PG_REGISTER for affected structs"
+    echo ""
+    exit 1
+fi
+
+if [ -n "$UPDATED" ]; then
+    echo ""
+    echo "📝 Database auto-updated for structs with version increments:"
+    echo -e "$UPDATED"
+    echo ""
+fi
+
+echo "✅ All PG struct sizes validated successfully"
+exit 0
diff --git a/cmake/extract-pg-sizes-nm.sh b/cmake/extract-pg-sizes-nm.sh
new file mode 100755
index 00000000000..70b37ec93f3
--- /dev/null
+++ b/cmake/extract-pg-sizes-nm.sh
@@ -0,0 +1,49 @@
+#!/bin/bash
+#
+# Extract PG struct sizes using nm (no extra dependencies)
+# Reads pgResetTemplate symbol sizes from symbol table
+#
+# Usage: extract-pg-sizes-nm.sh <elf_file>
+#
+
+set -euo pipefail
+
+ELF_FILE=$1
+
+if [ ! -f "$ELF_FILE" ]; then
+    echo "Error: ELF file not found: $ELF_FILE" >&2
+    exit 1
+fi
+
+echo "Extracting PG struct sizes from $ELF_FILE using nm..." >&2
+
+# Detect architecture for correct nm command
+if command -v arm-none-eabi-nm &> /dev/null && [[ $(file "$ELF_FILE") == *"ARM"* ]]; then
+    NM_CMD="arm-none-eabi-nm"
+else
+    NM_CMD="nm"
+fi
+
+# Extract pgResetTemplate symbols
+# Format: <addr> <size_hex> D pgResetTemplate_<name>
+$NM_CMD --print-size "$ELF_FILE" 2>/dev/null | grep "pgResetTemplate_" | \
+    while read addr size_hex type symbol; do
+        # Extract config name from symbol
+        # pgResetTemplate_blackboxConfig -> blackboxConfig
+        config_name="${symbol#pgResetTemplate_}"
+
+        # Convert hex size to decimal
+        size_dec=$((16#$size_hex))
+
+        # Find corresponding struct type from PG_REGISTER
+        struct_type=$(grep -rh "PG_REGISTER.*$config_name" src/main --include="*.c" 2>/dev/null | \
+            grep -oP 'PG_REGISTER[^(]*\(\K[^,]+' | head -1)
+
+        if [ -z "$struct_type" ]; then
+            # Fallback: convert config name to struct type
+            # blackboxConfig -> blackboxConfig_t
+            struct_type="${config_name}_t"
+        fi
+
+        printf "%-30s %s\n" "$struct_type" "$size_dec"
+    done | sort -u
diff --git a/cmake/main.cmake b/cmake/main.cmake
index d8e2dddf3ec..b7375cdb4ae 100644
--- a/cmake/main.cmake
+++ b/cmake/main.cmake
@@ -105,6 +105,13 @@ function(setup_firmware_target exe name)
     if(args_SKIP_RELEASES)
         set_target_properties(${exe} ${name} PROPERTIES SKIP_RELEASES ON)
     endif()
+
+    # Add PG struct size validation
+    add_custom_command(TARGET ${exe} POST_BUILD
+        COMMAND ${CMAKE_COMMAND} -E chdir ${CMAKE_SOURCE_DIR} ${CMAKE_SOURCE_DIR}/cmake/check-pg-struct-sizes.sh $<TARGET_FILE:${exe}>
+        COMMENT "Validating PG struct sizes for ${name}"
+        VERBATIM
+    )
 endfunction()
 
 function(exclude_from_all target)
diff --git a/cmake/pg_struct_sizes.db b/cmake/pg_struct_sizes.db
new file mode 100644
index 00000000000..f9dda814f67
--- /dev/null
+++ b/cmake/pg_struct_sizes.db
@@ -0,0 +1,49 @@
+# PG Struct Size Database
+# Format: struct_type size version
+# Generated from: build_sitl/bin/SITL.elf
+# Date: 2026-01-23 04:53:01 UTC
+
+adcChannelConfig_t               4 0
+armingConfig_t                   6 3
+barometerConfig_t                8 5
+batteryMetersConfig_t           36 2
+beeperConfig_t                  12 2
+blackboxConfig_t                16 4
+compassConfig_t                 32 6
+displayConfig_t                  1 0
+djiOsdConfig_t                   6 3
+ezTuneSettings_t                12 1
+failsafeConfig_t                22 3
+featureConfig_t                  4 0
+generalSettings_t                1 0
+geozone_config_t                20 0
+gimbalConfig_t                  10 1
+gimbalSerialConfig_t             1 0
+gpsConfig_t                     32 5
+gyroConfig_t                    28 12
+headTrackerConfig_t             16 1
+imuConfig_t                     16 2
+logConfig_t                      8 0
+modeActivationOperatorConfig_t   4 0
+motorConfig_t                   10 11
+navConfig_t                    156 7
+navFwAutolandConfig_t           16 0
+opticalFlowConfig_t              8 2
+osdCommonConfig_t                4 0
+osdConfig_t                    168 15
+pidAutotuneConfig_t             10 2
+pidProfile_t                   292 11
+pitotmeterConfig_t               8 2
+positionEstimationConfig_t      72 8
+powerLimitsConfig_t              8 1
+rangefinderConfig_t              2 3
+rcControlsConfig_t              10 4
+reversibleMotorsConfig_t         6 0
+rxConfig_t                      36 13
+servoConfig_t                   12 3
+statsConfig_t                   20 2
+systemConfig_t                  39 7
+telemetryConfig_t               64 8
+timeConfig_t                     4 1
+vtxConfig_t                     55 4
+vtxSettingsConfig_t             12 2