[SOLVED]Build a WR840N v2 firmware failure : rootfs offset aligned to *** error: images are too big by ***

[AndyX]

Hello, I'm a new to LEDE and apology my bad english.

I've read the basic developer guide from the LEDE website

I tried to build the firmware of [TL-WR840N V2 En] in the "windows subsystem for Linux" environment, but there was a problem when the firmware was final generated.

When I first configured, I just added Luci module & language package (because the default is disable), and then removed the USB module, and the output error log was as follows:

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dd if=/home/andyx/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/root.squashfs >> /home/andyx/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory.bin

6297+1 records in
6297+1 records out
3224122 bytes (3.2 MB, 3.1 MiB) copied, 0.239021 s, 13.5 MB/s

/home/andyx/lede/staging_dir/host/bin/mktplinkfw -H 0x08400002 -W 0x1 -F 4Mlzma -N OpenWrt -V r5616-67c1c14 -m 1 -k /home/andyx/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tl-wr840n-v2-kernel.bin -r /home/andyx/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory.bin -o /home/andyx/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory.bin.new -j -X 0x40000 -a 0x4   && mv /home/andyx/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory.bin.new /home/andyx/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory.bin || rm -f /home/andyx/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory.bin

**[mktplinkfw] rootfs offset aligned to 0x1421744**
**[mktplinkfw] *** error: images are too big by 975847 bytes**

cp /home/andyx/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory.bin /home/andyx/lede/bin/targets/ar71xx/generic/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory.bin

**cp: cannot stat '/home/andyx/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory.bin': No such file or directory**

Makefile:64: recipe for target '/home/andyx/lede/bin/targets/ar71xx/generic/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory.bin' **failed**

make[5]: [/home/andyx/lede/bin/targets/ar71xx/generic/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory.bin] **Error 1 (ignored)**

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So next, I tried to wipe configuration to default(make sure deleted Luci), and just removed the USB module, and the output error was the ...... same:

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dd if=/home/andyx/lede/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/root.squashfs >> /home/andyx/lede/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory-eu.bin

5846+1 records in
5846+1 records out
2993442 bytes (3.0 MB, 2.9 MiB) copied, 0.215815 s, 13.9 MB/s

/home/andyx/lede/lede/staging_dir/host/bin/mktplinkfw -H 0x08400002 -W 0x1 -F 4Mlzma -N OpenWrt -V r5616-67c1c14 -m 1 -k /home/andyx/lede/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tl-wr840n-v2-kernel.bin -r /home/andyx/lede/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory-eu.bin -o /home/andyx/lede/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory-eu.bin.new -j -X 0x40000 -a 0x4 -C EU  && mv /home/andyx/lede/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory-eu.bin.new /home/andyx/lede/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory-eu.bin || rm -f /home/andyx/lede/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory-eu.bin

**[mktplinkfw] rootfs offset aligned to 0x1421744**
**[mktplinkfw] error: images are too big by 745167 bytes**

cp /home/andyx/lede/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory-eu.bin /home/andyx/lede/lede/bin/targets/ar71xx/generic/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory-eu.bin

**cp: cannot stat '/home/andyx/lede/lede/build_dir/target-mips_24kc_musl/linux-ar71xx_generic/tmp/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory-eu.bin': No such file or directory**

Makefile:64: recipe for target '/home/andyx/lede/lede/bin/targets/ar71xx/generic/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory-eu.bin' **failed**

make[5]: [/home/andyx/lede/lede/bin/targets/ar71xx/generic/openwrt-ar71xx-generic-tl-wr840n-v2-squashfs-factory-eu.bin] **Error 1 (ignored)**

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All LEDE source code are placed under the "C:\Users****\AppData\Local\Packages\CanonicalGroupLimited.UbuntuonWindows_79rhkp1fndgsc\LocalState\rootfs\home****"path, No permission issue.

Try to run "make defconfig" & "make download V=99" is fine.

Does this look just images to big? what's the reason cause of this? How should I solve it?
I need help

[anon57995562]

WR840N only has 4 MB flash, so LuCI can't be installed...

https://lede-project.org/toh/hwdata/tp-link/tp-link_tl-wr840n_v2

https://lede-project.org/meta/infobox/432_warning

[AndyX]

Thank you for your reply!

So I tried to delete LUCI and USB support module to make the minimized firmware, but it still failed.

I find a Third-party firmware, It looks like modified from TL-WR841N v9, and it include Luci + OpenVPN + UPNP.

wr840nv2_en_tp_recovery.bin

I tried to flash in My [TL-WR840N v2 En] 4M flash, It working fine, except the router's LED are upside-down.

I don't know how he did it

[AndyX]

I found a solution! Refer the following link:

https://www.gargoyle-router.com/phpbb/viewtopic.php?f=7&t=8614

1-- Set SquashFS to 1024K
2-- Disable Kernel Debug
3-- Disable unnecessary package

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And I have referenced some configuration from following link:

Build for TP-Link TL-WR841N(D) [all versions]

[image] Sharing a custom build I've created for my own use: LEDE Reboot LuCI with https IPv6 and PPPoE MiniUPnP OpenVPN with mbed TLS QoS DDNS Wget with https Reghack (WiFi channels 12 and 13) Minified LuCI's CSS and JS Compiled with GCC 6.3 Removed kernel debugging Nothing else has been touched. Basically, it is a 'make defconfig' + profile + the mentioned above Free ROM: 76 KB OpenVPN AES-128-CBC speed: 12Mbs/12Mbs (measured on v8 downloading ubuntu via a …

THX for @amq

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OpenWRT Configuration：

_Target Devices -> TP-Link TL-WR840N-v2

【Enable】:
_Target Images -> squashfs -> Block size -> 1024
_Global build settings -> Strip unnecessary exports from the kernel image + Strip unnecessary functions from libraries
_LuCI -> Collections -> luci-ssl
_LuCI -> Applications -> luci-app-adblock
_LuCI -> Applications -> luci-app-ddns or luci-app-mqs
_LuCI -> Applications -> luci-app-upnp

【Disable】:
_Global build settings -> Kernel build options -> everything
_Global build settings -> Enable IPv6 support in package
_Kernel modules -> Wireless Drivers -> kmod-ath9k -> Support for Ubiquiti Unify Outdoor+
_Kernel modules -> Wireless Drivers -> kmod-mac80211 -> Export mac80211 internals in DebugFS
_Kernel modules -> Wireless Drivers -> kmod-ath -> Force Atheros drivers to respect the user's regdomain settings + Enable DFS support
_Kernel modules -> USB -> everything

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I build a Test version(LEDE TP-Link TL-WR840N-v2 For 4M flash):

OPENWRT/LEDE TP-LINK WR840N v2 (Eu) Special Firmware for 4M Flash

Function List:
SFE(Qualcomm FAST PATCH) / SQM-QOS / UPNP / IPv6 Support / VLAN Support / WIFI-Schedule / Bandwidth-Montior / ARP Binding / Wake-On-Lan / Auto Reboot

https://drive.google.com/open?id=1UoCyLy-1t_ilAhGPI7XsLV4GygRN1kDv

[Update 2018-Feb-4] v0.42 (English+Chinese)
LUCI-SFE-SQM-UPNP-IPv6-VLAN-WifiSchedule-BandwidthMontior-ArpBinding-WOL-AutoReboot