Due to new features being introduced and the general size increase of the Linux kernel, devices now need at least 8 MB of flash and 64 MB of RAM to run a default build of OpenWrt.
Depending upon which features you really need, you MIGHT be able to build a 24.10 customized image from src, fitting into 8/32. There are quite a lot of tweaks possible to reduce size of image. Especially makes sense, in case you have multiple devices of same type. I think, the real problem are the 32MB RAM only, because some programs have a higher initial mem requirement during startup. To introduce optimized sequential startup then.
This means your USB swap device called it a day. Probably where that extra megabyte v24 is needing got written in a bad sector that you did not reach with v23.
Hiding entire dmesg makes it impossible to help you in any way.
there is dd-wrt is that supports your device without swapping still in 2025.
OpenWrt allows to run a modern OS on vintage devices. But at some point, minimum requirements for OS reach the device specs. Some tweaks (@reinerotto) may allow to continue upgrading. Finally one must accept that the device will not be able to be upgraded anymore.
These devices can still be recycled as AP or pure switch for example, by getting rid of unnecessary functions.
I do have two devices, HLK device has a lot of RAM but it crashing sometimes due to know “timeout” issue. It have been few years with no patch. Can’t use the device.
I tested all recent versions of openwrt and find out that v21 works the best! Even wpad-mini works without OOM errors at full speed. Which is not works for v23 and v22. Sad to see openwrt goes memory hungry way.
To be clear.... this is not the fault of OpenWrt, per-se, but rather the growth in the Linux kernel.
Take a moment to consider how incredible it is that you're able to run the latest OpenWrt -- a full featured routing OS -- in just 64MB (that's megabytes) of RAM and 8MB of flash (minimum requirements). Compare that against any modern desktop OS and you're talking in the order of 4GB RAM and 64GB (that's gigabytes) of storage.
As the Linux kernel advances, it also grows in terms of resources required (RAM and storage). OpenWrt gets its kernel from the upstream in order to stay current with features, but more importantly security and functional compatibility.
No doubt about that. Is it just kernel? Maybe we can tweak compile flags and remove some security layers to reduce memory consumption? It would be even cooler to run recent openwrt on old hardware with basic features like ssh, routing, wpad-mini (no luci)
“ …. work best ….” Only to be confirmend after long term usage. Cause quite a few bug fixes in various drivers and packages between v21 and v24. However, CC might be “best” openwrt version for you
Other things do tend to grow a bit based on the kernel -- so dependencies such as kernel modules and the like will often get bigger, too. This overall slowly causes the system's total resource requirements to grow over time. There are other threads about this, including, IIRC, some that did some rough calculations showing the effect of the kernel vs other components.
I'm not a developer, so I cannot comment with any technical advice here. But would you really want to reduce the security posture of your router? This is the thing that keeps your network and devices safe from direct exposure to the internet. That's like the "3 little pigs" building a brick house and not installing windows or doors (just holes where they'd go).
Tweaking the kernel, drivers and core packages to fit into 32 MiB is a massive waste of time, and time is money. A 128/256 MiB OpenWrt-compatible device can be found within the $20-$40 price range, and I refuse to believe you can't make at least 4x that value in the time you would be spending hacking, compiling and testing.
This depends on. I did this tweaking several times for fleets of (identical) hotspot devices. There it makes commercial sense, and also regarding the environment, BTW. In case of single device only, you are definitely right. Although, good learning expirience, anyway