Thanks for the reply! I took a deeper look into the country codes showing up in the HTTP firmware upload - I do think it's a red herring (which is completely my fault for showing the HTTP firmware log vs the actual boot log) because when I upload the TP Link CA version firmware it does show similar errors:
fw type name : Cloud.
Firmware process common.
Image verify OK!
Firmware file Verify ok!
[Error]sysmgr_proinfo_buildStruct(): 647 @ unknown id(device_name), skip it.
[Error]sysmgr_cfg_checkSupportList(): 971 @ 00000000 NOT Match.
Firmwave supports, check OK.
(curFw_ver, newFw_ver) == (2.0, 2.0)
Firmware Recovery check ok!
upgrade_filecheck ok
HTTP upload is done! Upgrading...
do http upgrade
fw type name : Cloud.
Firmware process common.
Image verify OK!
Firmware file Verify ok!
[Error]sysmgr_proinfo_buildStruct(): 647 @ unknown id(device_name), skip it.
[Error]sysmgr_cfg_checkSupportList(): 971 @ 00000000 NOT Match.
Firmwave supports, check OK.
(curFw_ver, newFw_ver) == (2.0, 2.0)
Firmware Recovery check ok!
set integer flag to 0.
######################################################################
##########################################################
Done.
set integer flag to 1.
Firmware Recovery Success!
HTTP ugrade is done! Rebooting...
You can see that the sysmgr_cfg_checkSupportList
comes up with the good firmware. All that said, I did spend some time looking at the differences + similarities between the OpenWRT, TP Link CA, and TP Link US first 512-bytes and could not authoritatively say what the important values would be unfortunately. I'm happy to attach them if you'd like to look into them further though
Importantly, this time, I have the commands I ran and the log from the "Bad Magic" after attempting to boot the OpenWRT image:
ath> tftp 0x81000000 tp_recovery.bin
Trying eth0
eth0 link down
FAIL
Trying eth1
Using eth1 device
TFTP from server 192.168.0.10; our IP address is 192.168.0.1
Filename 'tp_recovery.bin'.
Load address: 0x81000000
Loading: #################################################################
<snip>
#####
done
Bytes transferred = 4684496 (477ad0 hex)
ath> erase 0x9f030000 +0x477ad0
Erasing flash...
First 0x3 last 0x4a sector size 0x10000
74
Erased 72 sectors
ath> cp.b 0x81000000 0x9f030000 0x477ad0
Copy to Flash... write addr: 9f030000
done
ath> reset
U-Boot 1.1.4 (Nov 29 2016 - 15:25:42)
ap151 - Dragonfly 1.0
DRAM: 64 MB
Top of RAM usable for U-Boot at: 84000000
Reserving 402k for U-Boot at: 83f98000
Reserving 32832k for malloc() at: 81f88000
Reserving 44 Bytes for Board Info at: 81f87fd4
Reserving 36 Bytes for Global Data at: 81f87fb0
Reserving 128k for boot params() at: 81f67fb0
Stack Pointer at: 81f67f98
Now running in RAM - U-Boot at: 83f98000
Flash Manuf Id 0xc8, DeviceId0 0x40, DeviceId1 0x17
flash size 8MB, sector count = 128
Flash: 8 MB
Using default environment
In: serial
Out: serial
Err: serial
Net: ath_gmac_enet_initialize...
No valid address in Flash. Using fixed address
No valid address in Flash. Using fixed address
ath_gmac_enet_initialize: reset mask:c02200
Dragonfly----> S27 PHY *
: cfg1 0x80000000 cfg2 0x7114
eth0: 00:03:7f:09:0b:ad
athrs27_phy_setup ATHR_PHY_CONTROL 4 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 4 :10
eth0 up
ATHRS27: resetting s27
ATHRS27: s27 reset done
: cfg1 0x800c0000 cfg2 0x7214
eth1: 00:03:7f:09:0b:ad
athrs27_phy_setup ATHR_PHY_CONTROL 0 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 0 :50
athrs27_phy_setup ATHR_PHY_CONTROL 1 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 1 :50
athrs27_phy_setup ATHR_PHY_CONTROL 2 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 2 :50
athrs27_phy_setup ATHR_PHY_CONTROL 3 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 3 :10
eth1 up
eth0, eth1
Setting 0x181162c0 to 0x82
Reading Partition Table from NVRAM ... OK
Parsing Partition Table ... OK
factory boot check integer ok.
load fs uboot at 0x10000.
Autobooting in 1 seconds
## Starting application at 0x80010000 ...
U-Boot 1.1.4 (Nov 29 2016 - 15:25:24)
ap151 - Dragonfly 1.0
DRAM: 64 MB
Top of RAM usable for U-Boot at: 84000000
Reserving 120k for U-Boot at: 83fe0000
Reserving 32832k for malloc() at: 81fd0000
Reserving 44 Bytes for Board Info at: 81fcffd4
Reserving 36 Bytes for Global Data at: 81fcffb0
Reserving 128k for boot params() at: 81faffb0
Stack Pointer at: 81faff98
Now running in RAM - U-Boot at: 83fe0000
Flash Manuf Id 0xc8, DeviceId0 0x40, DeviceId1 0x17
flash size 8MB, sector count = 128
Flash: 8 MB
Using default environment
In: serial
Out: serial
Err: serial
Net: ath_gmac_enet_initialize...
No valid address in Flash. Using fixed address
No valid address in Flash. Using fixed address
ath_gmac_enet_initialize: reset mask:c02200
Dragonfly----> S27 PHY *
: cfg1 0x80000000 cfg2 0x7114
eth0: 00:03:7f:09:0b:ad
athrs27_phy_setup ATHR_PHY_CONTROL 4 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 4 :10
eth0 up
ATHRS27: resetting s27
ATHRS27: s27 reset done
: cfg1 0x800c0000 cfg2 0x7214
eth1: 00:03:7f:09:0b:ad
athrs27_phy_setup ATHR_PHY_CONTROL 0 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 0 :10
athrs27_phy_setup ATHR_PHY_CONTROL 1 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 1 :10
athrs27_phy_setup ATHR_PHY_CONTROL 2 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 2 :10
athrs27_phy_setup ATHR_PHY_CONTROL 3 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 3 :10
eth1 up
eth0, eth1
Setting 0x181162c0 to 0x82
Autobooting in 1 seconds
## Booting image at 9f030000 ...
Bad Magic Number
ath>
Compared to the working TP Link CA version firmware:
U-Boot 1.1.4 (Nov 29 2016 - 15:25:42)
ap151 - Dragonfly 1.0
DRAM: 64 MB
Top of RAM usable for U-Boot at: 84000000
Reserving 402k for U-Boot at: 83f98000
Reserving 32832k for malloc() at: 81f88000
Reserving 44 Bytes for Board Info at: 81f87fd4
Reserving 36 Bytes for Global Data at: 81f87fb0
Reserving 128k for boot params() at: 81f67fb0
Stack Pointer at: 81f67f98
Now running in RAM - U-Boot at: 83f98000
Flash Manuf Id 0xc8, DeviceId0 0x40, DeviceId1 0x17
flash size 8MB, sector count = 128
Flash: 8 MB
Using default environment
In: serial
Out: serial
Err: serial
Net: ath_gmac_enet_initialize...
No valid address in Flash. Using fixed address
No valid address in Flash. Using fixed address
ath_gmac_enet_initialize: reset mask:c02200
Dragonfly----> S27 PHY *
: cfg1 0x80000000 cfg2 0x7114
eth0: 00:03:7f:09:0b:ad
athrs27_phy_setup ATHR_PHY_CONTROL 4 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 4 :10
eth0 up
ATHRS27: resetting s27
ATHRS27: s27 reset done
: cfg1 0x800c0000 cfg2 0x7214
eth1: 00:03:7f:09:0b:ad
athrs27_phy_setup ATHR_PHY_CONTROL 0 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 0 :50
athrs27_phy_setup ATHR_PHY_CONTROL 1 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 1 :50
athrs27_phy_setup ATHR_PHY_CONTROL 2 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 2 :50
athrs27_phy_setup ATHR_PHY_CONTROL 3 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 3 :50
eth1 up
eth0, eth1
Setting 0x181162c0 to 0x82
Reading Partition Table from NVRAM ... OK
Parsing Partition Table ... OK
factory boot check integer ok.
load fs uboot at 0x10000.
Autobooting in 1 seconds
## Starting application at 0x80010000 ...
U-Boot 1.1.4 (Nov 29 2016 - 15:25:24)
ap151 - Dragonfly 1.0
DRAM: 64 MB
Top of RAM usable for U-Boot at: 84000000
Reserving 120k for U-Boot at: 83fe0000
Reserving 32832k for malloc() at: 81fd0000
Reserving 44 Bytes for Board Info at: 81fcffd4
Reserving 36 Bytes for Global Data at: 81fcffb0
Reserving 128k for boot params() at: 81faffb0
Stack Pointer at: 81faff98
Now running in RAM - U-Boot at: 83fe0000
Flash Manuf Id 0xc8, DeviceId0 0x40, DeviceId1 0x17
flash size 8MB, sector count = 128
Flash: 8 MB
Using default environment
In: serial
Out: serial
Err: serial
Net: ath_gmac_enet_initialize...
No valid address in Flash. Using fixed address
No valid address in Flash. Using fixed address
ath_gmac_enet_initialize: reset mask:c02200
Dragonfly----> S27 PHY *
: cfg1 0x80000000 cfg2 0x7114
eth0: 00:03:7f:09:0b:ad
athrs27_phy_setup ATHR_PHY_CONTROL 4 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 4 :10
eth0 up
ATHRS27: resetting s27
ATHRS27: s27 reset done
: cfg1 0x800c0000 cfg2 0x7214
eth1: 00:03:7f:09:0b:ad
athrs27_phy_setup ATHR_PHY_CONTROL 0 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 0 :10
athrs27_phy_setup ATHR_PHY_CONTROL 1 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 1 :10
athrs27_phy_setup ATHR_PHY_CONTROL 2 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 2 :10
athrs27_phy_setup ATHR_PHY_CONTROL 3 :1000
athrs27_phy_setup ATHR_PHY_SPEC_STAUS 3 :10
eth1 up
eth0, eth1
Setting 0x181162c0 to 0x82
Autobooting in 1 seconds
## Booting image at 9f030000 ...
Image Name: MIPS OpenWrt Linux-3.3.8
Created: 2016-12-06 7:00:35 UTC
Image Type: MIPS Linux Multi-File Image (lzma compressed)
Data Size: 1042944 Bytes = 1018.5 kB
Load Address: 80060000
Entry Point: 80060000
Contents:
Image 0: 1042936 Bytes = 1018.5 kB
Verifying Checksum at 0x9f030040 ...OK
Uncompressing Multi-File Image ... OK
No initrd
## Transferring control to Linux (at address 80060000) ...
## Giving linux memsize in bytes, 67108864
Starting kernel ...
<boots successfully into the TP Link software>
Interestingly, the TP Link firmware boots an imaged named "OpenWRT Linux".
I hope this provides a little extra clarity to my original post with more pertinent logs?