From 86247026be930223c109ae7b0c701a6baf57043d Mon Sep 17 00:00:00 2001
From: Ray Morris <deepmagicbeginshere@gmail.com>
Date: Thu, 22 Jan 2026 16:02:22 -0600
Subject: [PATCH 1/5] Fix PG version check to detect cross-file struct changes
MIME-Version: 1.0
Content-Type: text/plain; charset=UTF-8
Content-Transfer-Encoding: 8bit

PROBLEM:
PR #11276 modified blackboxConfig_s struct in blackbox.h without
incrementing version in blackbox.c, and the workflow didn't catch it.

ROOT CAUSE:
Script processed files independently:
- Checked blackbox.c → found PG_REGISTER but struct not in this file
- Checked blackbox.h → found struct change but no PG_REGISTER
- Never connected the two pieces together

SOLUTION:
1. Expand file list to include companions that contain PG_REGISTER
   (if blackbox.h changed, also check blackbox.c for PG_REGISTER)

2. Search ALL changed files for struct definitions
   (when checking PG_REGISTER in blackbox.c, search all changed
   files including blackbox.h for the struct)

3. Detect when struct changed but PG_REGISTER wasn't touched
   (empty old_version and new_version → version not incremented)

This correctly catches the most common bug: developer modifies struct
in header file but forgets to increment version in source file.
---
 .github/scripts/check-pg-versions.sh | 116 ++++++++++++++++++---------
 1 file changed, 78 insertions(+), 38 deletions(-)

diff --git a/.github/scripts/check-pg-versions.sh b/.github/scripts/check-pg-versions.sh
index 9a15be8913a..e07f7538fda 100755
--- a/.github/scripts/check-pg-versions.sh
+++ b/.github/scripts/check-pg-versions.sh
@@ -59,8 +59,8 @@ 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
+    # Check if file contains PG_REGISTER in current version
+    if ! git show $HEAD_COMMIT:"$file" 2>/dev/null | grep -q "PG_REGISTER"; then
         return 0
     fi
 
@@ -93,26 +93,25 @@ check_file_for_pg_changes() {
 
             echo "    📋 Found: $struct_type (version $version)"
 
-            # Check if this struct's typedef was modified
+            # Check if this struct's typedef was modified in ANY changed file
             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
+            local struct_body_diff=""
+            local struct_found_in=""
+
+            # Search all changed files for this struct definition
+            while IFS= read -r changed_file; do
+                [ -z "$changed_file" ] && continue
+
+                local file_diff=$(git diff $BASE_COMMIT..$HEAD_COMMIT -- "$changed_file")
+                local struct_in_file=$(echo "$file_diff" | sed -n "/${struct_pattern}/,/\}.*${struct_type};/p")
 
-                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}/,/\}.*${struct_type};/p")
+                if [ -n "$struct_in_file" ]; then
+                    struct_body_diff="$struct_in_file"
+                    struct_found_in="$changed_file"
+                    echo "    🔍 Found struct definition in $changed_file"
+                    break
                 fi
-            fi
+            done <<< "$CHANGED_FILES"
 
             local struct_changes=$(echo "$struct_body_diff" | grep -E "^[-+]" \
                 | grep -v -E "^[-+]\s*(typedef struct|}|//|\*)" \
@@ -121,42 +120,48 @@ check_file_for_pg_changes() {
                 | tr -d '[:space:]')
 
             if [ -n "$struct_changes" ]; then
-                echo "    ⚠️  Struct definition modified"
+                echo "    ⚠️  Struct definition modified in $struct_found_in"
 
-                # Check if version was incremented in this diff
+                # Check if version was incremented in PG_REGISTER
                 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 "")
 
+                # Find line number of PG_REGISTER for error reporting
+                local line_num=$(git show $HEAD_COMMIT:"$file" | grep -n "PG_REGISTER.*$struct_type" | cut -d: -f1 | head -1)
+
                 if [ -n "$old_version" ] && [ -n "$new_version" ]; then
+                    # PG_REGISTER was modified - check if version increased
                     if [ "$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
+- **Struct modified:** Field changes detected in $struct_found_in
 - **Version status:** ❌ Not incremented (version $version)
-- **Recommendation:** Review changes and increment version if needed
+- **Recommendation:** Increment version from $old_version to $(($old_version + 1))
 
 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.*$struct_type" | cut -d: -f1 | head -1)
+                elif [ -z "$old_version" ] && [ -z "$new_version" ]; then
+                    # PG_REGISTER wasn't modified but struct was - THIS IS THE BUG!
+                    echo "    ❌ PG_REGISTER not modified, version still $version"
+                    cat >> $ISSUES_FILE << EOF
+### \`$struct_type\` ($file:$line_num)
+- **Struct modified:** Field changes detected in $struct_found_in
+- **Version status:** ❌ Not incremented (still version $version)
+- **Recommendation:** Increment version to $(($version + 1)) in $file
 
+EOF
+                else
+                    # One exists but not the other - unusual edge case
+                    echo "    ⚠️  Unusual version change pattern detected"
                     cat >> $ISSUES_FILE << EOF
 ### \`$struct_type\` ($file:$line_num)
-- **Struct modified:** Field changes detected
-- **Version status:** ⚠️  Unable to verify version increment
+- **Struct modified:** Field changes detected in $struct_found_in
+- **Version status:** ⚠️ Unusual change pattern (old: ${old_version:-none}, new: ${new_version:-none})
 - **Current version:** $version
-- **Recommendation:** Verify version was incremented if struct layout changed
+- **Recommendation:** Manually verify version increment
 
 EOF
                 fi
@@ -167,11 +172,46 @@ EOF
     done <<< "$pg_registers"
 }
 
-# Check each changed file
+# Build list of files to check (changed files + companions with PG_REGISTER)
+echo "🔍 Building file list including companions with PG_REGISTER..."
+FILES_TO_CHECK=""
+ALREADY_ADDED=""
+
 while IFS= read -r file; do
-    check_file_for_pg_changes "$file"
+    [ -z "$file" ] && continue
+
+    # Add this file to check list
+    if ! echo "$ALREADY_ADDED" | grep -qw "$file"; then
+        FILES_TO_CHECK="$FILES_TO_CHECK$file"$'\n'
+        ALREADY_ADDED="$ALREADY_ADDED $file"
+    fi
+
+    # Determine companion file (.c <-> .h)
+    local companion=""
+    if [[ "$file" == *.c ]]; then
+        companion="${file%.c}.h"
+    elif [[ "$file" == *.h ]]; then
+        companion="${file%.h}.c"
+    fi
+
+    # If companion exists and contains PG_REGISTER, add it to check list
+    if [ -n "$companion" ]; then
+        if git show $HEAD_COMMIT:"$companion" 2>/dev/null | grep -q "PG_REGISTER"; then
+            if ! echo "$ALREADY_ADDED" | grep -qw "$companion"; then
+                echo "  📎 Adding $companion (companion of $file with PG_REGISTER)"
+                FILES_TO_CHECK="$FILES_TO_CHECK$companion"$'\n'
+                ALREADY_ADDED="$ALREADY_ADDED $companion"
+            fi
+        fi
+    fi
 done <<< "$CHANGED_FILES"
 
+# Check each file (including companions)
+while IFS= read -r file; do
+    [ -z "$file" ] && continue
+    check_file_for_pg_changes "$file"
+done <<< "$FILES_TO_CHECK"
+
 # Check if any issues were found
 if [ -s $ISSUES_FILE ]; then
     echo ""

From fb95e9f19530e9d1a4f2cdd77b6957f28ff7f337 Mon Sep 17 00:00:00 2001
From: Ray Morris <deepmagicbeginshere@gmail.com>
Date: Fri, 23 Jan 2026 10:07:37 -0600
Subject: [PATCH 2/5] Add build-time PG struct size validation

Implement automated validation of parameter group struct sizes during
firmware builds to prevent settings corruption from struct changes
without version increments.

Features:
- Validates all PG struct sizes against database after each build
- Fails build if size changed without PG version increment
- Auto-updates database when version IS properly incremented
- No extra dependencies (uses standard nm tool)
- Works on SITL and all hardware targets

Implementation:
- check-pg-struct-sizes.sh: Build-time validation script
- extract-pg-sizes-nm.sh: Extract sizes from binaries using nm
- generate-pg-database.sh: Generate database with sizes + versions
- pg_struct_sizes.db: Database of 44 PG structs with current sizes/versions
- Integrated into cmake/main.cmake as POST_BUILD step

Testing verified:
- Passes when no changes made
- Fails when size changed without version increment
- Passes and auto-updates when size changed with version increment
- Database unchanged when validation fails

Complements existing GitHub Action PR check with compile-time validation.
---
 cmake/PG-SIZE-EXTRACTION-NM.md     | 205 +++++++++++++++++++++++++++++
 cmake/PG-SIZE-EXTRACTION-PAHOLE.md |  96 ++++++++++++++
 cmake/PG-STRUCT-VALIDATION.md      | 138 +++++++++++++++++++
 cmake/check-pg-struct-sizes.sh     | 121 +++++++++++++++++
 cmake/compare-pg-sizes-nm.sh       |  88 +++++++++++++
 cmake/extract-pg-sizes-nm.sh       |  50 +++++++
 cmake/generate-pg-database.sh      |  63 +++++++++
 cmake/main.cmake                   |   7 +
 cmake/pg_struct_sizes.db           |  49 +++++++
 9 files changed, 817 insertions(+)
 create mode 100644 cmake/PG-SIZE-EXTRACTION-NM.md
 create mode 100644 cmake/PG-SIZE-EXTRACTION-PAHOLE.md
 create mode 100644 cmake/PG-STRUCT-VALIDATION.md
 create mode 100755 cmake/check-pg-struct-sizes.sh
 create mode 100755 cmake/compare-pg-sizes-nm.sh
 create mode 100755 cmake/extract-pg-sizes-nm.sh
 create mode 100755 cmake/generate-pg-database.sh
 create mode 100644 cmake/pg_struct_sizes.db

diff --git a/cmake/PG-SIZE-EXTRACTION-NM.md b/cmake/PG-SIZE-EXTRACTION-NM.md
new file mode 100644
index 00000000000..0a413dee15a
--- /dev/null
+++ b/cmake/PG-SIZE-EXTRACTION-NM.md
@@ -0,0 +1,205 @@
+# PG Struct Size Extraction Using nm (No Extra Dependencies)
+
+## Overview
+
+Extract PG struct sizes directly from compiled binaries using `nm` from standard binutils.
+
+## Advantages Over pahole Approach
+
+✅ **No extra dependencies** - `nm` is part of binutils (already required for builds)
+✅ **Works without debug info** - Reads symbol table, not DWARF
+✅ **Faster** - Direct symbol table lookup
+✅ **Simpler** - Standard tool, no special packages needed
+
+## Dependencies
+
+- `nm` (part of binutils, already required)
+- For ARM targets: `arm-none-eabi-nm` (already required)
+
+## How It Works
+
+1. PG system stores reset templates in `.data` section
+2. Each template symbol is named: `pgResetTemplate_<configName>`
+3. Symbol table includes size of each reset template
+4. Reset template size = `sizeof(struct)`
+
+## Usage
+
+### Extract All PG Struct Sizes
+
+```bash
+cmake/extract-pg-sizes-nm.sh build_sitl/bin/SITL.elf
+```
+
+**Sample Output:**
+```
+adcChannelConfig_t             4
+armingConfig_t                 6
+barometerConfig_t              8
+batteryMetersConfig_t          24
+beeperConfig_t                 12
+blackboxConfig_t               16
+compassConfig_t                24
+displayConfig_t                1
+djiOsdConfig_t                 6
+...
+```
+
+### Compare Across Platforms
+
+```bash
+cmake/compare-pg-sizes-nm.sh build/bin/SPEEDYBEEF405V3.elf build/bin/MATEKF722.elf build/bin/MATEKH743.elf
+```
+
+**Sample Output:**
+```
+Comparing PG struct sizes across platforms...
+
+Struct                         SPEEDYBEEF405V3       MATEKF722       MATEKH743
+============================== =============== =============== ===============
+adcChannelConfig_t                          4B              4B              4B
+armingConfig_t                              6B              6B              6B
+barometerConfig_t                           8B              8B              8B
+batteryMetersConfig_t                      24B             24B             24B
+blackboxConfig_t                           16B             16B             16B
+...
+```
+
+## Verified Results (2026-01-22)
+
+Compared PG struct sizes across three platforms:
+- **SPEEDYBEEF405V3** (STM32F405 - Cortex-M4)
+- **MATEKF722** (STM32F722 - Cortex-M7)
+- **MATEKH743** (STM32H743 - Cortex-M7)
+
+**Finding:** ✅ **All PG struct sizes are identical across F4, F7, and H7 platforms**
+
+No platform-specific size differences detected across 47 PG structs.
+
+## Implementation Details
+
+### Symbol Format
+
+```
+$ nm --print-size build_sitl/bin/SITL.elf | grep pgResetTemplate_blackboxConfig
+00000000000df71c 0000000000000010 D pgResetTemplate_blackboxConfig
+      ↑                  ↑          ↑ ↑
+   address          size (hex)   type name
+```
+
+- **Address**: Location in memory (not relevant for size extraction)
+- **Size**: Template size in hexadecimal = `sizeof(struct)`
+- **Type**: D = data section
+- **Name**: `pgResetTemplate_<configName>`
+
+### Conversion Process
+
+1. Extract symbol name: `pgResetTemplate_blackboxConfig` → `blackboxConfig`
+2. Convert hex size to decimal: `0x10` → `16`
+3. Find struct type from `PG_REGISTER`: `blackboxConfig` → `blackboxConfig_t`
+4. Output: `blackboxConfig_t 16`
+
+## Build-Time Validation Workflow
+
+### 1. Generate Initial Database
+
+```bash
+# Build with any target
+make sitl
+
+# Extract sizes
+cmake/extract-pg-sizes-nm.sh build_sitl/bin/SITL.elf > cmake/pg_struct_sizes.db
+
+# Add PG versions from source
+# (Script to be created that merges sizes with versions from PG_REGISTER)
+```
+
+### 2. Validate On Each Build
+
+```bash
+# After compilation
+cmake/check-pg-struct-sizes.sh build_sitl/bin/SITL.elf
+
+# Exits with error if:
+# - Struct size changed BUT
+# - PG version was NOT incremented
+```
+
+### 3. Update Database After Valid Changes
+
+```bash
+# After incrementing PG version for legitimate changes
+cmake/extract-pg-sizes-nm.sh build_sitl/bin/SITL.elf > cmake/pg_struct_sizes.db
+git add cmake/pg_struct_sizes.db
+git commit -m "Update PG sizes after blackbox version increment"
+```
+
+## Limitations
+
+- **Size only, not layout** - Cannot detect field reordering with same total size
+- **Platform consistency assumed** - Works because INAV PG structs don't use platform-specific types
+
+## Files Created
+
+- `extract-pg-sizes-nm.sh` - Extract sizes from single binary
+- `compare-pg-sizes-nm.sh` - Compare sizes across multiple binaries
+- `check-pg-struct-sizes.sh` - Validate sizes against database (TODO)
+- `pg_struct_sizes.db` - Database of struct sizes + versions (TODO)
+
+## Build-Time Validation - IMPLEMENTED
+
+### Created Scripts
+
+1. **`check-pg-struct-sizes.sh`** - Validates sizes against database
+   - Extracts current sizes from binary
+   - Compares against `pg_struct_sizes.db`
+   - Gets PG versions from source code
+   - Fails build if size changed without version increment
+
+2. **`generate-pg-database.sh`** - Generates database from binary
+   - Extracts sizes using `extract-pg-sizes-nm.sh`
+   - Looks up PG versions from source
+   - Output format: `struct_type size version`
+
+3. **`pg_struct_sizes.db`** - Database of 47 PG structs with sizes and versions
+
+### Integration
+
+Modified `cmake/main.cmake` - Added POST_BUILD validation to `setup_firmware_target()`:
+
+```cmake
+# Add PG struct size validation
+add_custom_command(TARGET ${exe} POST_BUILD
+    COMMAND ${CMAKE_SOURCE_DIR}/cmake/check-pg-struct-sizes.sh $<TARGET_FILE:${exe}>
+    COMMENT "Validating PG struct sizes for ${name}"
+    VERBATIM
+)
+```
+
+### Testing Required
+
+Build SITL to verify validation runs:
+```bash
+make sitl
+```
+
+Expected output at end of build:
+```
+🔍 Checking PG struct sizes against database...
+  ✓ adcChannelConfig_t (4B)
+  ...
+✅ All PG struct sizes validated successfully
+```
+
+## Comparison with pahole
+
+| Feature | nm Approach | pahole Approach |
+|---------|-------------|-----------------|
+| Extra dependencies | ❌ None | ✅ Requires dwarves package |
+| Debug info required | ❌ No | ✅ Yes |
+| Shows field layout | ❌ No | ✅ Yes (with offsets, padding) |
+| Detects reordering | ❌ No | ✅ Yes |
+| Build time | ⚡ Fast | 🐌 Slower (DWARF parsing) |
+| Works on stripped binaries | ✅ Yes (symbol table sufficient) | ❌ No |
+
+**Recommendation:** Use nm approach for build-time validation (fast, no dependencies). Use pahole for detailed struct analysis during development.
diff --git a/cmake/PG-SIZE-EXTRACTION-PAHOLE.md b/cmake/PG-SIZE-EXTRACTION-PAHOLE.md
new file mode 100644
index 00000000000..a2eeef4d5c0
--- /dev/null
+++ b/cmake/PG-SIZE-EXTRACTION-PAHOLE.md
@@ -0,0 +1,96 @@
+# PG Struct Size Extraction Using pahole
+
+## Overview
+
+Extract PG struct sizes from compiled binaries using `pahole` (part of dwarves package).
+
+## Dependencies
+
+```bash
+# Install pahole
+sudo apt install dwarves
+```
+
+## How It Works
+
+1. Build with debug info (default): `make sitl`
+2. Binary contains DWARF debug information with complete struct layouts
+3. `pahole` reads DWARF and displays struct members, sizes, padding
+
+## Usage
+
+### Extract Single Struct
+
+```bash
+pahole -C barometerConfig_s build_sitl/bin/SITL.elf
+```
+
+**Output:**
+```
+struct barometerConfig_s {
+	uint8_t                    baro_hardware;        /*     0     1 */
+
+	/* XXX 1 byte hole, try to pack */
+
+	uint16_t                   baro_calibration_tolerance; /*     2     2 */
+	float                      baro_temp_correction; /*     4     4 */
+
+	/* size: 8, cachelines: 1, members: 3 */
+	/* sum members: 7, holes: 1, sum holes: 1 */
+	/* last cacheline: 8 bytes */
+};
+```
+
+### Extract Just Size
+
+```bash
+pahole -C barometerConfig_s build_sitl/bin/SITL.elf | grep "size:"
+# Output: /* size: 8, cachelines: 1, members: 3 */
+
+# Extract number only:
+pahole -C barometerConfig_s build_sitl/bin/SITL.elf | grep "size:" | grep -oP 'size: \K\d+'
+# Output: 8
+```
+
+### Extract All PG Struct Sizes
+
+```bash
+for struct in barometerConfig_s blackboxConfig_s navConfig_s; do
+  size=$(pahole -C "$struct" build_sitl/bin/SITL.elf 2>/dev/null | grep "size:" | grep -oP 'size: \K\d+')
+  echo "${struct%_s}_t: ${size:-N/A} bytes"
+done
+```
+
+**Output:**
+```
+barometerConfig_t: 8 bytes
+blackboxConfig_t: 16 bytes
+navConfig_t: 156 bytes
+```
+
+## Tested Results
+
+From SITL build on 2026-01-22:
+
+| Struct Type | Size (bytes) | Notes |
+|-------------|--------------|-------|
+| barometerConfig_t | 8 | 1 byte hole for alignment |
+| blackboxConfig_t | 16 | - |
+| navConfig_t | 156 | - |
+
+## Advantages
+
+✅ **Detailed layout information** - Shows field offsets, padding, holes
+✅ **Any architecture** - Works on ARM, x86-64, etc.
+✅ **Reliable** - Uses standard DWARF debug format
+✅ **Helps optimization** - Identifies padding that could be eliminated
+
+## Disadvantages
+
+❌ **Extra dependency** - Requires dwarves package (not in standard build tools)
+❌ **Requires debug info** - Won't work on stripped/release builds
+❌ **Slower** - Parsing DWARF is more expensive than reading symbol table
+
+## Alternative: nm-based approach
+
+For build-time validation without extra dependencies, use `nm` to read symbol sizes directly (see PG-SIZE-EXTRACTION-NM.md).
diff --git a/cmake/PG-STRUCT-VALIDATION.md b/cmake/PG-STRUCT-VALIDATION.md
new file mode 100644
index 00000000000..56b81a5ff4b
--- /dev/null
+++ b/cmake/PG-STRUCT-VALIDATION.md
@@ -0,0 +1,138 @@
+# PG Struct Layout Validation
+
+Build-time validation to detect parameter group struct changes without version increments.
+
+## How It Works
+
+1. **DWARF Debug Info** - Compiler embeds complete struct layout in `.elf` debug sections
+2. **Layout Extraction** - `readelf` extracts field offsets and types (no extra dependencies)
+3. **Checksum Database** - Stores MD5 of each PG struct's layout
+4. **Build Check** - Compares current layout vs database, fails if mismatch without version increment
+
+## Advantages Over Git Hook
+
+✅ **No filename assumptions** - Works even when struct is in `battery_config_structs.h` but PG_REGISTER in `battery.c`
+
+✅ **Catches all layout changes:**
+- Field additions/removals (git hook ✓)
+- Field reordering same-size types (git hook ✗)
+- Type changes with same size (git hook ✗)
+- Packing attribute changes (git hook ✗)
+
+✅ **No git required** - Works on fresh clone without history
+
+✅ **Compiler-verified** - Uses same preprocessed view compiler sees
+
+## Setup
+
+### Initial Database Generation
+
+```bash
+# Build SITL with debug info (default)
+make clean_sitl
+make sitl
+
+# Generate initial database
+cmake/generate-pg-struct-database.sh build/inav_SITL
+
+# Commit the database
+git add cmake/pg_struct_checksums.db
+git commit -m "Add PG struct layout database"
+```
+
+### Integration Into Makefile
+
+Add to `Makefile`:
+
+```makefile
+# After SITL build completes
+sitl: $(SITL_TARGET)
+	@echo "Validating PG struct layouts..."
+	@cmake/check-pg-struct-layouts.sh $(SITL_TARGET) || \
+		(echo "ERROR: PG struct layout changed without version increment!" && false)
+```
+
+## Workflow
+
+### Normal Development (No PG Changes)
+
+```bash
+make sitl
+# → Build succeeds, validation passes
+```
+
+### Developer Modifies PG Struct (Forgot Version Increment)
+
+```bash
+# Edit src/main/blackbox/blackbox.h
+# - Remove field from blackboxConfig_s
+
+make sitl
+# → Build completes
+# → Validation FAILS:
+#
+#   ❌ ERROR: blackboxConfig_t layout changed but version NOT incremented
+#      File: src/main/blackbox/blackbox.c:102
+#      ACTION REQUIRED: Increment PG version from 4 to 5
+```
+
+### Developer Fixes Version
+
+```bash
+# Edit src/main/blackbox/blackbox.c
+# Change: PG_REGISTER(blackboxConfig_t, ..., 4);
+# To:     PG_REGISTER(blackboxConfig_t, ..., 5);
+
+make sitl
+# → Validation passes but warns:
+#
+#   ✅ Version incremented (4 → 5)
+#      Note: Update database with: make update-pg-db
+```
+
+### Update Database
+
+```bash
+make update-pg-db
+# Or manually:
+cmake/generate-pg-struct-database.sh build/inav_SITL
+
+git add cmake/pg_struct_checksums.db
+git commit -m "Update PG database after blackbox version increment"
+```
+
+## Files
+
+- `extract-pg-struct-layout.sh` - Extract struct layout from DWARF debug info
+- `check-pg-struct-layouts.sh` - Validate layouts against database
+- `generate-pg-struct-database.sh` - Create/update database from current build
+- `pg_struct_checksums.db` - Database of struct checksums (committed to git)
+
+## Limitations
+
+- **Size-only for Release Builds** - Release builds strip debug info, can only check sizeof() not layout
+- **Requires Debug Build** - Full validation needs `-g` flag (default for SITL)
+- **Database Maintenance** - Database must be updated after legitimate version increments
+
+## Alternative: Size-Only Check
+
+For release builds without debug info, fallback to size-only validation:
+
+```bash
+# Extract sizes using nm or objdump instead of DWARF
+# Less comprehensive but works without debug info
+```
+
+## Why Better Than Git Hook?
+
+**Git Hook Issues:**
+1. Assumes matching filenames (`blackbox.h` ↔ `blackbox.c`)
+2. Fails when struct in `battery_config_structs.h` but PG in `battery.c`
+3. Can't detect field reordering
+4. Needs full git history
+
+**Build-Time Check:**
+1. Works regardless of file names
+2. Detects all layout changes
+3. Works on fresh clones
+4. Validated by compiler preprocessor
diff --git a/cmake/check-pg-struct-sizes.sh b/cmake/check-pg-struct-sizes.sh
new file mode 100755
index 00000000000..93530149ece
--- /dev/null
+++ b/cmake/check-pg-struct-sizes.sh
@@ -0,0 +1,121 @@
+#!/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
+        echo "  ℹ️  New: $struct_type (${current_size}B)"
+        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/compare-pg-sizes-nm.sh b/cmake/compare-pg-sizes-nm.sh
new file mode 100755
index 00000000000..d6539a4e9a9
--- /dev/null
+++ b/cmake/compare-pg-sizes-nm.sh
@@ -0,0 +1,88 @@
+#!/bin/bash
+#
+# Compare PG struct sizes across multiple binaries
+# Uses nm to read symbol table (no extra dependencies)
+#
+
+set -euo pipefail
+
+if [ $# -lt 2 ]; then
+    echo "Usage: $0 <elf1> <elf2> [elf3...]" >&2
+    echo "Example: $0 build/MATEKF405.elf build/MATEKF722.elf build/MATEKH743.elf" >&2
+    exit 1
+fi
+
+SCRIPT_DIR=$(dirname "$0")
+ELF_FILES=("$@")
+
+echo "Comparing PG struct sizes across platforms..."
+echo ""
+
+# Extract sizes from each binary into temp files
+declare -a TEMP_FILES
+for i in "${!ELF_FILES[@]}"; do
+    TEMP_FILES[$i]=$(mktemp)
+    "$SCRIPT_DIR/extract-pg-sizes-nm.sh" "${ELF_FILES[$i]}" 2>/dev/null > "${TEMP_FILES[$i]}"
+done
+
+# Get union of all struct names
+ALL_STRUCTS=$(cat "${TEMP_FILES[@]}" | cut -d' ' -f1 | sort -u)
+
+# Print header
+printf "%-30s" "Struct"
+for elf in "${ELF_FILES[@]}"; do
+    basename=$(basename "$elf" | sed 's/.elf$//')
+    printf " %15s" "$basename"
+done
+printf "\n"
+
+printf "%-30s" "=============================="
+for elf in "${ELF_FILES[@]}"; do
+    printf " %15s" "==============="
+done
+printf "\n"
+
+# For each struct, show size from each binary
+while read -r struct; do
+    printf "%-30s" "$struct"
+
+    sizes=()
+    for temp_file in "${TEMP_FILES[@]}"; do
+        size=$(grep "^$struct " "$temp_file" 2>/dev/null | awk '{print $2}')
+
+        if [ -z "$size" ]; then
+            printf " %15s" "N/A"
+        else
+            printf " %15s" "${size}B"
+            sizes+=("$size")
+        fi
+    done
+
+    # Check if all sizes are the same
+    if [ ${#sizes[@]} -gt 1 ]; then
+        first="${sizes[0]}"
+        all_same=1
+        for s in "${sizes[@]}"; do
+            if [ "$s" != "$first" ]; then
+                all_same=0
+                break
+            fi
+        done
+
+        if [ $all_same -eq 0 ]; then
+            printf " ⚠️ MISMATCH"
+        fi
+    fi
+
+    printf "\n"
+done <<< "$ALL_STRUCTS"
+
+# Cleanup
+for temp_file in "${TEMP_FILES[@]}"; do
+    rm -f "$temp_file"
+done
+
+echo ""
+echo "Legend:"
+echo "  N/A = Struct not found in this platform's binary"
+echo "  ⚠️ MISMATCH = Struct has different sizes across platforms"
diff --git a/cmake/extract-pg-sizes-nm.sh b/cmake/extract-pg-sizes-nm.sh
new file mode 100755
index 00000000000..bdfeb369be6
--- /dev/null
+++ b/cmake/extract-pg-sizes-nm.sh
@@ -0,0 +1,50 @@
+#!/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 $ELF_FILE using nm..." >&2
+
+# Detect architecture for correct nm command
+ARCH=$(file "$ELF_FILE" | grep -o "x86-64\|ARM" || echo "unknown")
+if [[ "$ARCH" == "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/generate-pg-database.sh b/cmake/generate-pg-database.sh
new file mode 100755
index 00000000000..c785886adc4
--- /dev/null
+++ b/cmake/generate-pg-database.sh
@@ -0,0 +1,63 @@
+#!/bin/bash
+#
+# Generate PG struct sizes database with versions
+# Extracts sizes from binary and versions from source code
+#
+# Usage: generate-pg-database.sh <elf_file> > pg_struct_sizes.db
+#
+
+set -euo pipefail
+
+ELF_FILE=$1
+SCRIPT_DIR=$(dirname "$0")
+
+if [ ! -f "$ELF_FILE" ]; then
+    echo "Error: ELF file not found: $ELF_FILE" >&2
+    exit 1
+fi
+
+echo "# PG Struct Size Database" >&2
+echo "# Format: struct_type size version" >&2
+echo "# Generated from: $ELF_FILE" >&2
+echo "# Date: $(date -u '+%Y-%m-%d %H:%M:%S UTC')" >&2
+echo "" >&2
+
+# 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 "$version"
+}
+
+# Extract sizes from binary
+TEMP_SIZES=$(mktemp)
+"$SCRIPT_DIR/extract-pg-sizes-nm.sh" "$ELF_FILE" 2>/dev/null > "$TEMP_SIZES"
+
+# For each struct, add version from source
+while read -r struct_type size; do
+    [ -z "$struct_type" ] && continue
+
+    version=$(get_pg_version "$struct_type")
+
+    if [ -z "$version" ]; then
+        echo "Warning: Cannot find PG version for $struct_type" >&2
+        version="0"
+    fi
+
+    # Output: struct_type size version
+    printf "%-30s %3s %s\n" "$struct_type" "$size" "$version"
+
+done < "$TEMP_SIZES"
+
+rm -f "$TEMP_SIZES"
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

From 333fdf5520778052d17175423edaf2ff29ca56c5 Mon Sep 17 00:00:00 2001
From: Ray Morris <deepmagicbeginshere@gmail.com>
Date: Fri, 23 Jan 2026 11:15:32 -0600
Subject: [PATCH 3/5] Address code review feedback from qodo-code-review bot

1. Fix bash runtime error: Remove 'local' keyword from top-level variable
   - .github/scripts/check-pg-versions.sh:190
   - Variable 'companion' was declared with 'local' outside of a function

2. Add auto-addition of new PG structs to database
   - cmake/check-pg-struct-sizes.sh
   - New structs with PG_REGISTER are automatically added to database
   - Tracks additions in update report

3. Improve architecture detection robustness
   - cmake/extract-pg-sizes-nm.sh:26
   - Check for arm-none-eabi-nm existence before use
   - Use more robust file type checking

Note: Keeping automatic database updates when version IS incremented
as per original design requirement.
---
 .github/scripts/check-pg-versions.sh |  2 +-
 cmake/check-pg-struct-sizes.sh       | 16 ++++++++++++++--
 cmake/extract-pg-sizes-nm.sh         |  3 +--
 3 files changed, 16 insertions(+), 5 deletions(-)

diff --git a/.github/scripts/check-pg-versions.sh b/.github/scripts/check-pg-versions.sh
index e07f7538fda..649ab5f7269 100755
--- a/.github/scripts/check-pg-versions.sh
+++ b/.github/scripts/check-pg-versions.sh
@@ -187,7 +187,7 @@ while IFS= read -r file; do
     fi
 
     # Determine companion file (.c <-> .h)
-    local companion=""
+    companion=""
     if [[ "$file" == *.c ]]; then
         companion="${file%.c}.h"
     elif [[ "$file" == *.h ]]; then
diff --git a/cmake/check-pg-struct-sizes.sh b/cmake/check-pg-struct-sizes.sh
index 93530149ece..fcbbbcac0ed 100755
--- a/cmake/check-pg-struct-sizes.sh
+++ b/cmake/check-pg-struct-sizes.sh
@@ -60,8 +60,20 @@ while read -r struct_type current_size; do
     db_entry=$(grep "^$struct_type " "$DB_FILE" 2>/dev/null || echo "")
 
     if [ -z "$db_entry" ]; then
-        # New struct not in database
-        echo "  ℹ️  New: $struct_type (${current_size}B)"
+        # 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
 
diff --git a/cmake/extract-pg-sizes-nm.sh b/cmake/extract-pg-sizes-nm.sh
index bdfeb369be6..70b37ec93f3 100755
--- a/cmake/extract-pg-sizes-nm.sh
+++ b/cmake/extract-pg-sizes-nm.sh
@@ -18,8 +18,7 @@ fi
 echo "Extracting PG struct sizes from $ELF_FILE using nm..." >&2
 
 # Detect architecture for correct nm command
-ARCH=$(file "$ELF_FILE" | grep -o "x86-64\|ARM" || echo "unknown")
-if [[ "$ARCH" == "ARM" ]]; then
+if command -v arm-none-eabi-nm &> /dev/null && [[ $(file "$ELF_FILE") == *"ARM"* ]]; then
     NM_CMD="arm-none-eabi-nm"
 else
     NM_CMD="nm"

From 177518dc8cd300cb8aae971a433ac7adc2b842b5 Mon Sep 17 00:00:00 2001
From: Ray Morris <deepmagicbeginshere@gmail.com>
Date: Fri, 23 Jan 2026 13:24:31 -0600
Subject: [PATCH 4/5] Remove internal documentation and redundant utility
 scripts

Removed files not needed in public release:
- cmake/PG-SIZE-EXTRACTION-NM.md (internal process documentation)
- cmake/PG-SIZE-EXTRACTION-PAHOLE.md (alternative approach documentation)
- cmake/PG-STRUCT-VALIDATION.md (internal design documentation)
- cmake/generate-pg-database.sh (replaced by auto-add feature in check script)
- cmake/compare-pg-sizes-nm.sh (developer utility, not needed for builds)

Remaining files provide core build-time validation:
- cmake/check-pg-struct-sizes.sh (main validation script)
- cmake/extract-pg-sizes-nm.sh (size extraction utility)
- cmake/pg_struct_sizes.db (struct size database)
---
 cmake/PG-SIZE-EXTRACTION-NM.md     | 205 -----------------------------
 cmake/PG-SIZE-EXTRACTION-PAHOLE.md |  96 --------------
 cmake/PG-STRUCT-VALIDATION.md      | 138 -------------------
 cmake/compare-pg-sizes-nm.sh       |  88 -------------
 cmake/generate-pg-database.sh      |  63 ---------
 5 files changed, 590 deletions(-)
 delete mode 100644 cmake/PG-SIZE-EXTRACTION-NM.md
 delete mode 100644 cmake/PG-SIZE-EXTRACTION-PAHOLE.md
 delete mode 100644 cmake/PG-STRUCT-VALIDATION.md
 delete mode 100755 cmake/compare-pg-sizes-nm.sh
 delete mode 100755 cmake/generate-pg-database.sh

diff --git a/cmake/PG-SIZE-EXTRACTION-NM.md b/cmake/PG-SIZE-EXTRACTION-NM.md
deleted file mode 100644
index 0a413dee15a..00000000000
--- a/cmake/PG-SIZE-EXTRACTION-NM.md
+++ /dev/null
@@ -1,205 +0,0 @@
-# PG Struct Size Extraction Using nm (No Extra Dependencies)
-
-## Overview
-
-Extract PG struct sizes directly from compiled binaries using `nm` from standard binutils.
-
-## Advantages Over pahole Approach
-
-✅ **No extra dependencies** - `nm` is part of binutils (already required for builds)
-✅ **Works without debug info** - Reads symbol table, not DWARF
-✅ **Faster** - Direct symbol table lookup
-✅ **Simpler** - Standard tool, no special packages needed
-
-## Dependencies
-
-- `nm` (part of binutils, already required)
-- For ARM targets: `arm-none-eabi-nm` (already required)
-
-## How It Works
-
-1. PG system stores reset templates in `.data` section
-2. Each template symbol is named: `pgResetTemplate_<configName>`
-3. Symbol table includes size of each reset template
-4. Reset template size = `sizeof(struct)`
-
-## Usage
-
-### Extract All PG Struct Sizes
-
-```bash
-cmake/extract-pg-sizes-nm.sh build_sitl/bin/SITL.elf
-```
-
-**Sample Output:**
-```
-adcChannelConfig_t             4
-armingConfig_t                 6
-barometerConfig_t              8
-batteryMetersConfig_t          24
-beeperConfig_t                 12
-blackboxConfig_t               16
-compassConfig_t                24
-displayConfig_t                1
-djiOsdConfig_t                 6
-...
-```
-
-### Compare Across Platforms
-
-```bash
-cmake/compare-pg-sizes-nm.sh build/bin/SPEEDYBEEF405V3.elf build/bin/MATEKF722.elf build/bin/MATEKH743.elf
-```
-
-**Sample Output:**
-```
-Comparing PG struct sizes across platforms...
-
-Struct                         SPEEDYBEEF405V3       MATEKF722       MATEKH743
-============================== =============== =============== ===============
-adcChannelConfig_t                          4B              4B              4B
-armingConfig_t                              6B              6B              6B
-barometerConfig_t                           8B              8B              8B
-batteryMetersConfig_t                      24B             24B             24B
-blackboxConfig_t                           16B             16B             16B
-...
-```
-
-## Verified Results (2026-01-22)
-
-Compared PG struct sizes across three platforms:
-- **SPEEDYBEEF405V3** (STM32F405 - Cortex-M4)
-- **MATEKF722** (STM32F722 - Cortex-M7)
-- **MATEKH743** (STM32H743 - Cortex-M7)
-
-**Finding:** ✅ **All PG struct sizes are identical across F4, F7, and H7 platforms**
-
-No platform-specific size differences detected across 47 PG structs.
-
-## Implementation Details
-
-### Symbol Format
-
-```
-$ nm --print-size build_sitl/bin/SITL.elf | grep pgResetTemplate_blackboxConfig
-00000000000df71c 0000000000000010 D pgResetTemplate_blackboxConfig
-      ↑                  ↑          ↑ ↑
-   address          size (hex)   type name
-```
-
-- **Address**: Location in memory (not relevant for size extraction)
-- **Size**: Template size in hexadecimal = `sizeof(struct)`
-- **Type**: D = data section
-- **Name**: `pgResetTemplate_<configName>`
-
-### Conversion Process
-
-1. Extract symbol name: `pgResetTemplate_blackboxConfig` → `blackboxConfig`
-2. Convert hex size to decimal: `0x10` → `16`
-3. Find struct type from `PG_REGISTER`: `blackboxConfig` → `blackboxConfig_t`
-4. Output: `blackboxConfig_t 16`
-
-## Build-Time Validation Workflow
-
-### 1. Generate Initial Database
-
-```bash
-# Build with any target
-make sitl
-
-# Extract sizes
-cmake/extract-pg-sizes-nm.sh build_sitl/bin/SITL.elf > cmake/pg_struct_sizes.db
-
-# Add PG versions from source
-# (Script to be created that merges sizes with versions from PG_REGISTER)
-```
-
-### 2. Validate On Each Build
-
-```bash
-# After compilation
-cmake/check-pg-struct-sizes.sh build_sitl/bin/SITL.elf
-
-# Exits with error if:
-# - Struct size changed BUT
-# - PG version was NOT incremented
-```
-
-### 3. Update Database After Valid Changes
-
-```bash
-# After incrementing PG version for legitimate changes
-cmake/extract-pg-sizes-nm.sh build_sitl/bin/SITL.elf > cmake/pg_struct_sizes.db
-git add cmake/pg_struct_sizes.db
-git commit -m "Update PG sizes after blackbox version increment"
-```
-
-## Limitations
-
-- **Size only, not layout** - Cannot detect field reordering with same total size
-- **Platform consistency assumed** - Works because INAV PG structs don't use platform-specific types
-
-## Files Created
-
-- `extract-pg-sizes-nm.sh` - Extract sizes from single binary
-- `compare-pg-sizes-nm.sh` - Compare sizes across multiple binaries
-- `check-pg-struct-sizes.sh` - Validate sizes against database (TODO)
-- `pg_struct_sizes.db` - Database of struct sizes + versions (TODO)
-
-## Build-Time Validation - IMPLEMENTED
-
-### Created Scripts
-
-1. **`check-pg-struct-sizes.sh`** - Validates sizes against database
-   - Extracts current sizes from binary
-   - Compares against `pg_struct_sizes.db`
-   - Gets PG versions from source code
-   - Fails build if size changed without version increment
-
-2. **`generate-pg-database.sh`** - Generates database from binary
-   - Extracts sizes using `extract-pg-sizes-nm.sh`
-   - Looks up PG versions from source
-   - Output format: `struct_type size version`
-
-3. **`pg_struct_sizes.db`** - Database of 47 PG structs with sizes and versions
-
-### Integration
-
-Modified `cmake/main.cmake` - Added POST_BUILD validation to `setup_firmware_target()`:
-
-```cmake
-# Add PG struct size validation
-add_custom_command(TARGET ${exe} POST_BUILD
-    COMMAND ${CMAKE_SOURCE_DIR}/cmake/check-pg-struct-sizes.sh $<TARGET_FILE:${exe}>
-    COMMENT "Validating PG struct sizes for ${name}"
-    VERBATIM
-)
-```
-
-### Testing Required
-
-Build SITL to verify validation runs:
-```bash
-make sitl
-```
-
-Expected output at end of build:
-```
-🔍 Checking PG struct sizes against database...
-  ✓ adcChannelConfig_t (4B)
-  ...
-✅ All PG struct sizes validated successfully
-```
-
-## Comparison with pahole
-
-| Feature | nm Approach | pahole Approach |
-|---------|-------------|-----------------|
-| Extra dependencies | ❌ None | ✅ Requires dwarves package |
-| Debug info required | ❌ No | ✅ Yes |
-| Shows field layout | ❌ No | ✅ Yes (with offsets, padding) |
-| Detects reordering | ❌ No | ✅ Yes |
-| Build time | ⚡ Fast | 🐌 Slower (DWARF parsing) |
-| Works on stripped binaries | ✅ Yes (symbol table sufficient) | ❌ No |
-
-**Recommendation:** Use nm approach for build-time validation (fast, no dependencies). Use pahole for detailed struct analysis during development.
diff --git a/cmake/PG-SIZE-EXTRACTION-PAHOLE.md b/cmake/PG-SIZE-EXTRACTION-PAHOLE.md
deleted file mode 100644
index a2eeef4d5c0..00000000000
--- a/cmake/PG-SIZE-EXTRACTION-PAHOLE.md
+++ /dev/null
@@ -1,96 +0,0 @@
-# PG Struct Size Extraction Using pahole
-
-## Overview
-
-Extract PG struct sizes from compiled binaries using `pahole` (part of dwarves package).
-
-## Dependencies
-
-```bash
-# Install pahole
-sudo apt install dwarves
-```
-
-## How It Works
-
-1. Build with debug info (default): `make sitl`
-2. Binary contains DWARF debug information with complete struct layouts
-3. `pahole` reads DWARF and displays struct members, sizes, padding
-
-## Usage
-
-### Extract Single Struct
-
-```bash
-pahole -C barometerConfig_s build_sitl/bin/SITL.elf
-```
-
-**Output:**
-```
-struct barometerConfig_s {
-	uint8_t                    baro_hardware;        /*     0     1 */
-
-	/* XXX 1 byte hole, try to pack */
-
-	uint16_t                   baro_calibration_tolerance; /*     2     2 */
-	float                      baro_temp_correction; /*     4     4 */
-
-	/* size: 8, cachelines: 1, members: 3 */
-	/* sum members: 7, holes: 1, sum holes: 1 */
-	/* last cacheline: 8 bytes */
-};
-```
-
-### Extract Just Size
-
-```bash
-pahole -C barometerConfig_s build_sitl/bin/SITL.elf | grep "size:"
-# Output: /* size: 8, cachelines: 1, members: 3 */
-
-# Extract number only:
-pahole -C barometerConfig_s build_sitl/bin/SITL.elf | grep "size:" | grep -oP 'size: \K\d+'
-# Output: 8
-```
-
-### Extract All PG Struct Sizes
-
-```bash
-for struct in barometerConfig_s blackboxConfig_s navConfig_s; do
-  size=$(pahole -C "$struct" build_sitl/bin/SITL.elf 2>/dev/null | grep "size:" | grep -oP 'size: \K\d+')
-  echo "${struct%_s}_t: ${size:-N/A} bytes"
-done
-```
-
-**Output:**
-```
-barometerConfig_t: 8 bytes
-blackboxConfig_t: 16 bytes
-navConfig_t: 156 bytes
-```
-
-## Tested Results
-
-From SITL build on 2026-01-22:
-
-| Struct Type | Size (bytes) | Notes |
-|-------------|--------------|-------|
-| barometerConfig_t | 8 | 1 byte hole for alignment |
-| blackboxConfig_t | 16 | - |
-| navConfig_t | 156 | - |
-
-## Advantages
-
-✅ **Detailed layout information** - Shows field offsets, padding, holes
-✅ **Any architecture** - Works on ARM, x86-64, etc.
-✅ **Reliable** - Uses standard DWARF debug format
-✅ **Helps optimization** - Identifies padding that could be eliminated
-
-## Disadvantages
-
-❌ **Extra dependency** - Requires dwarves package (not in standard build tools)
-❌ **Requires debug info** - Won't work on stripped/release builds
-❌ **Slower** - Parsing DWARF is more expensive than reading symbol table
-
-## Alternative: nm-based approach
-
-For build-time validation without extra dependencies, use `nm` to read symbol sizes directly (see PG-SIZE-EXTRACTION-NM.md).
diff --git a/cmake/PG-STRUCT-VALIDATION.md b/cmake/PG-STRUCT-VALIDATION.md
deleted file mode 100644
index 56b81a5ff4b..00000000000
--- a/cmake/PG-STRUCT-VALIDATION.md
+++ /dev/null
@@ -1,138 +0,0 @@
-# PG Struct Layout Validation
-
-Build-time validation to detect parameter group struct changes without version increments.
-
-## How It Works
-
-1. **DWARF Debug Info** - Compiler embeds complete struct layout in `.elf` debug sections
-2. **Layout Extraction** - `readelf` extracts field offsets and types (no extra dependencies)
-3. **Checksum Database** - Stores MD5 of each PG struct's layout
-4. **Build Check** - Compares current layout vs database, fails if mismatch without version increment
-
-## Advantages Over Git Hook
-
-✅ **No filename assumptions** - Works even when struct is in `battery_config_structs.h` but PG_REGISTER in `battery.c`
-
-✅ **Catches all layout changes:**
-- Field additions/removals (git hook ✓)
-- Field reordering same-size types (git hook ✗)
-- Type changes with same size (git hook ✗)
-- Packing attribute changes (git hook ✗)
-
-✅ **No git required** - Works on fresh clone without history
-
-✅ **Compiler-verified** - Uses same preprocessed view compiler sees
-
-## Setup
-
-### Initial Database Generation
-
-```bash
-# Build SITL with debug info (default)
-make clean_sitl
-make sitl
-
-# Generate initial database
-cmake/generate-pg-struct-database.sh build/inav_SITL
-
-# Commit the database
-git add cmake/pg_struct_checksums.db
-git commit -m "Add PG struct layout database"
-```
-
-### Integration Into Makefile
-
-Add to `Makefile`:
-
-```makefile
-# After SITL build completes
-sitl: $(SITL_TARGET)
-	@echo "Validating PG struct layouts..."
-	@cmake/check-pg-struct-layouts.sh $(SITL_TARGET) || \
-		(echo "ERROR: PG struct layout changed without version increment!" && false)
-```
-
-## Workflow
-
-### Normal Development (No PG Changes)
-
-```bash
-make sitl
-# → Build succeeds, validation passes
-```
-
-### Developer Modifies PG Struct (Forgot Version Increment)
-
-```bash
-# Edit src/main/blackbox/blackbox.h
-# - Remove field from blackboxConfig_s
-
-make sitl
-# → Build completes
-# → Validation FAILS:
-#
-#   ❌ ERROR: blackboxConfig_t layout changed but version NOT incremented
-#      File: src/main/blackbox/blackbox.c:102
-#      ACTION REQUIRED: Increment PG version from 4 to 5
-```
-
-### Developer Fixes Version
-
-```bash
-# Edit src/main/blackbox/blackbox.c
-# Change: PG_REGISTER(blackboxConfig_t, ..., 4);
-# To:     PG_REGISTER(blackboxConfig_t, ..., 5);
-
-make sitl
-# → Validation passes but warns:
-#
-#   ✅ Version incremented (4 → 5)
-#      Note: Update database with: make update-pg-db
-```
-
-### Update Database
-
-```bash
-make update-pg-db
-# Or manually:
-cmake/generate-pg-struct-database.sh build/inav_SITL
-
-git add cmake/pg_struct_checksums.db
-git commit -m "Update PG database after blackbox version increment"
-```
-
-## Files
-
-- `extract-pg-struct-layout.sh` - Extract struct layout from DWARF debug info
-- `check-pg-struct-layouts.sh` - Validate layouts against database
-- `generate-pg-struct-database.sh` - Create/update database from current build
-- `pg_struct_checksums.db` - Database of struct checksums (committed to git)
-
-## Limitations
-
-- **Size-only for Release Builds** - Release builds strip debug info, can only check sizeof() not layout
-- **Requires Debug Build** - Full validation needs `-g` flag (default for SITL)
-- **Database Maintenance** - Database must be updated after legitimate version increments
-
-## Alternative: Size-Only Check
-
-For release builds without debug info, fallback to size-only validation:
-
-```bash
-# Extract sizes using nm or objdump instead of DWARF
-# Less comprehensive but works without debug info
-```
-
-## Why Better Than Git Hook?
-
-**Git Hook Issues:**
-1. Assumes matching filenames (`blackbox.h` ↔ `blackbox.c`)
-2. Fails when struct in `battery_config_structs.h` but PG in `battery.c`
-3. Can't detect field reordering
-4. Needs full git history
-
-**Build-Time Check:**
-1. Works regardless of file names
-2. Detects all layout changes
-3. Works on fresh clones
-4. Validated by compiler preprocessor
diff --git a/cmake/compare-pg-sizes-nm.sh b/cmake/compare-pg-sizes-nm.sh
deleted file mode 100755
index d6539a4e9a9..00000000000
--- a/cmake/compare-pg-sizes-nm.sh
+++ /dev/null
@@ -1,88 +0,0 @@
-#!/bin/bash
-#
-# Compare PG struct sizes across multiple binaries
-# Uses nm to read symbol table (no extra dependencies)
-#
-
-set -euo pipefail
-
-if [ $# -lt 2 ]; then
-    echo "Usage: $0 <elf1> <elf2> [elf3...]" >&2
-    echo "Example: $0 build/MATEKF405.elf build/MATEKF722.elf build/MATEKH743.elf" >&2
-    exit 1
-fi
-
-SCRIPT_DIR=$(dirname "$0")
-ELF_FILES=("$@")
-
-echo "Comparing PG struct sizes across platforms..."
-echo ""
-
-# Extract sizes from each binary into temp files
-declare -a TEMP_FILES
-for i in "${!ELF_FILES[@]}"; do
-    TEMP_FILES[$i]=$(mktemp)
-    "$SCRIPT_DIR/extract-pg-sizes-nm.sh" "${ELF_FILES[$i]}" 2>/dev/null > "${TEMP_FILES[$i]}"
-done
-
-# Get union of all struct names
-ALL_STRUCTS=$(cat "${TEMP_FILES[@]}" | cut -d' ' -f1 | sort -u)
-
-# Print header
-printf "%-30s" "Struct"
-for elf in "${ELF_FILES[@]}"; do
-    basename=$(basename "$elf" | sed 's/.elf$//')
-    printf " %15s" "$basename"
-done
-printf "\n"
-
-printf "%-30s" "=============================="
-for elf in "${ELF_FILES[@]}"; do
-    printf " %15s" "==============="
-done
-printf "\n"
-
-# For each struct, show size from each binary
-while read -r struct; do
-    printf "%-30s" "$struct"
-
-    sizes=()
-    for temp_file in "${TEMP_FILES[@]}"; do
-        size=$(grep "^$struct " "$temp_file" 2>/dev/null | awk '{print $2}')
-
-        if [ -z "$size" ]; then
-            printf " %15s" "N/A"
-        else
-            printf " %15s" "${size}B"
-            sizes+=("$size")
-        fi
-    done
-
-    # Check if all sizes are the same
-    if [ ${#sizes[@]} -gt 1 ]; then
-        first="${sizes[0]}"
-        all_same=1
-        for s in "${sizes[@]}"; do
-            if [ "$s" != "$first" ]; then
-                all_same=0
-                break
-            fi
-        done
-
-        if [ $all_same -eq 0 ]; then
-            printf " ⚠️ MISMATCH"
-        fi
-    fi
-
-    printf "\n"
-done <<< "$ALL_STRUCTS"
-
-# Cleanup
-for temp_file in "${TEMP_FILES[@]}"; do
-    rm -f "$temp_file"
-done
-
-echo ""
-echo "Legend:"
-echo "  N/A = Struct not found in this platform's binary"
-echo "  ⚠️ MISMATCH = Struct has different sizes across platforms"
diff --git a/cmake/generate-pg-database.sh b/cmake/generate-pg-database.sh
deleted file mode 100755
index c785886adc4..00000000000
--- a/cmake/generate-pg-database.sh
+++ /dev/null
@@ -1,63 +0,0 @@
-#!/bin/bash
-#
-# Generate PG struct sizes database with versions
-# Extracts sizes from binary and versions from source code
-#
-# Usage: generate-pg-database.sh <elf_file> > pg_struct_sizes.db
-#
-
-set -euo pipefail
-
-ELF_FILE=$1
-SCRIPT_DIR=$(dirname "$0")
-
-if [ ! -f "$ELF_FILE" ]; then
-    echo "Error: ELF file not found: $ELF_FILE" >&2
-    exit 1
-fi
-
-echo "# PG Struct Size Database" >&2
-echo "# Format: struct_type size version" >&2
-echo "# Generated from: $ELF_FILE" >&2
-echo "# Date: $(date -u '+%Y-%m-%d %H:%M:%S UTC')" >&2
-echo "" >&2
-
-# 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 "$version"
-}
-
-# Extract sizes from binary
-TEMP_SIZES=$(mktemp)
-"$SCRIPT_DIR/extract-pg-sizes-nm.sh" "$ELF_FILE" 2>/dev/null > "$TEMP_SIZES"
-
-# For each struct, add version from source
-while read -r struct_type size; do
-    [ -z "$struct_type" ] && continue
-
-    version=$(get_pg_version "$struct_type")
-
-    if [ -z "$version" ]; then
-        echo "Warning: Cannot find PG version for $struct_type" >&2
-        version="0"
-    fi
-
-    # Output: struct_type size version
-    printf "%-30s %3s %s\n" "$struct_type" "$size" "$version"
-
-done < "$TEMP_SIZES"
-
-rm -f "$TEMP_SIZES"

From 2fe7469dcc3b852100954a60751ace6b8a4422cd Mon Sep 17 00:00:00 2001
From: Ray Morris <deepmagicbeginshere@gmail.com>
Date: Fri, 23 Jan 2026 14:39:06 -0600
Subject: [PATCH 5/5] Remove GitHub Action in favor of build-time validation

Removed:
- .github/scripts/check-pg-versions.sh (GitHub Action script)
- .github/workflows/pg-version-check.yml (GitHub Action workflow)

The build-time validation in cmake/check-pg-struct-sizes.sh provides
superior coverage:
- Catches issues during every build (not just PRs)
- Works for local development builds
- Auto-updates database when versions are incremented
- Auto-adds new PG structs to database
- Provides immediate developer feedback

The GitHub Action approach is redundant with build-time validation.
---
 .github/scripts/check-pg-versions.sh   | 226 -------------------------
 .github/workflows/pg-version-check.yml | 128 --------------
 2 files changed, 354 deletions(-)
 delete mode 100755 .github/scripts/check-pg-versions.sh
 delete mode 100644 .github/workflows/pg-version-check.yml

diff --git a/.github/scripts/check-pg-versions.sh b/.github/scripts/check-pg-versions.sh
deleted file mode 100755
index 649ab5f7269..00000000000
--- a/.github/scripts/check-pg-versions.sh
+++ /dev/null
@@ -1,226 +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 current version
-    if ! git show $HEAD_COMMIT:"$file" 2>/dev/null | 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 in ANY changed file
-            local struct_pattern="typedef struct ${struct_type%_t}_s"
-            local struct_body_diff=""
-            local struct_found_in=""
-
-            # Search all changed files for this struct definition
-            while IFS= read -r changed_file; do
-                [ -z "$changed_file" ] && continue
-
-                local file_diff=$(git diff $BASE_COMMIT..$HEAD_COMMIT -- "$changed_file")
-                local struct_in_file=$(echo "$file_diff" | sed -n "/${struct_pattern}/,/\}.*${struct_type};/p")
-
-                if [ -n "$struct_in_file" ]; then
-                    struct_body_diff="$struct_in_file"
-                    struct_found_in="$changed_file"
-                    echo "    🔍 Found struct definition in $changed_file"
-                    break
-                fi
-            done <<< "$CHANGED_FILES"
-
-            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 in $struct_found_in"
-
-                # Check if version was incremented in PG_REGISTER
-                local old_version=$(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 "")
-
-                # Find line number of PG_REGISTER for error reporting
-                local line_num=$(git show $HEAD_COMMIT:"$file" | grep -n "PG_REGISTER.*$struct_type" | cut -d: -f1 | head -1)
-
-                if [ -n "$old_version" ] && [ -n "$new_version" ]; then
-                    # PG_REGISTER was modified - check if version increased
-                    if [ "$new_version" -le "$old_version" ]; then
-                        echo "    ❌ Version NOT incremented ($old_version → $new_version)"
-                        cat >> $ISSUES_FILE << EOF
-### \`$struct_type\` ($file:$line_num)
-- **Struct modified:** Field changes detected in $struct_found_in
-- **Version status:** ❌ Not incremented (version $version)
-- **Recommendation:** Increment version from $old_version to $(($old_version + 1))
-
-EOF
-                    else
-                        echo "    ✅ Version incremented ($old_version → $new_version)"
-                    fi
-                elif [ -z "$old_version" ] && [ -z "$new_version" ]; then
-                    # PG_REGISTER wasn't modified but struct was - THIS IS THE BUG!
-                    echo "    ❌ PG_REGISTER not modified, version still $version"
-                    cat >> $ISSUES_FILE << EOF
-### \`$struct_type\` ($file:$line_num)
-- **Struct modified:** Field changes detected in $struct_found_in
-- **Version status:** ❌ Not incremented (still version $version)
-- **Recommendation:** Increment version to $(($version + 1)) in $file
-
-EOF
-                else
-                    # One exists but not the other - unusual edge case
-                    echo "    ⚠️  Unusual version change pattern detected"
-                    cat >> $ISSUES_FILE << EOF
-### \`$struct_type\` ($file:$line_num)
-- **Struct modified:** Field changes detected in $struct_found_in
-- **Version status:** ⚠️ Unusual change pattern (old: ${old_version:-none}, new: ${new_version:-none})
-- **Current version:** $version
-- **Recommendation:** Manually verify version increment
-
-EOF
-                fi
-            else
-                echo "    ✅ Struct unchanged"
-            fi
-        fi
-    done <<< "$pg_registers"
-}
-
-# Build list of files to check (changed files + companions with PG_REGISTER)
-echo "🔍 Building file list including companions with PG_REGISTER..."
-FILES_TO_CHECK=""
-ALREADY_ADDED=""
-
-while IFS= read -r file; do
-    [ -z "$file" ] && continue
-
-    # Add this file to check list
-    if ! echo "$ALREADY_ADDED" | grep -qw "$file"; then
-        FILES_TO_CHECK="$FILES_TO_CHECK$file"$'\n'
-        ALREADY_ADDED="$ALREADY_ADDED $file"
-    fi
-
-    # Determine companion file (.c <-> .h)
-    companion=""
-    if [[ "$file" == *.c ]]; then
-        companion="${file%.c}.h"
-    elif [[ "$file" == *.h ]]; then
-        companion="${file%.h}.c"
-    fi
-
-    # If companion exists and contains PG_REGISTER, add it to check list
-    if [ -n "$companion" ]; then
-        if git show $HEAD_COMMIT:"$companion" 2>/dev/null | grep -q "PG_REGISTER"; then
-            if ! echo "$ALREADY_ADDED" | grep -qw "$companion"; then
-                echo "  📎 Adding $companion (companion of $file with PG_REGISTER)"
-                FILES_TO_CHECK="$FILES_TO_CHECK$companion"$'\n'
-                ALREADY_ADDED="$ALREADY_ADDED $companion"
-            fi
-        fi
-    fi
-done <<< "$CHANGED_FILES"
-
-# Check each file (including companions)
-while IFS= read -r file; do
-    [ -z "$file" ] && continue
-    check_file_for_pg_changes "$file"
-done <<< "$FILES_TO_CHECK"
-
-# 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}`);
-            }