Hi Peter,
I also got this router. Love OpenWrt but I'm not really willing to run trunk or beta builds on my routers. I'll try to answer your questions and hopefully provide you with my result.
1) sysupgrade images are just to upgrade already installed OpenWrt installs. It won't fix the kernel compatibility issue with the zioncluster.ca firmware. That firmware is using kernel 3.18.27, where CC 15.05.1 is kernel 3.18.23.
2) See link below for the config I generated. I have no idea where to find what the OpenWrt maintainers use (seems this would be pretty important for generating repeatable builds, but maybe they don't care about that). My config includes the ath10k stuff as well as what appears to be the "stock" packages for other ar71xx firmwares (I based my list on a stock WNDR3700v2 which is also ar71xx generic).
3) Easily the biggest pain in the ass. What I ended up doing was logging into my WNDR3700v2 running CC15.05.1 and noticed its r48532. From there I could download the tree from https://dev.openwrt.org/browser/branche … order=name (use the download link at the bottom of the page). That gets you the tree for 15.05.1 but the feeds.conf.default just references git branches. And those branches have seen updates since 15.05.1 was built. So for that, I just ended up going through each of the 5 default feeds and correlating the latest commit to what's on my stock WNDR3700v2. I can't guarantee they're exactly the same, but they should be damn close.
4) Lastly, I applied the 49220 changeset to enable support for gd25q128 in my build.
The whole goal here was to build something as close as possible to stock 15.05.1, but with support for gd25q128 (and kmod-ath10k and ath10k-firmware included). Since its very close or identical to stock CC 15.05.1, it should work with those packages as well.
Unfortunately, I did not have time to port the mktplinkfirmware changes such that it builds region compatible firmwares. You'll still have to use tftp or the "flash to dd-wrt, flash revert, flash openwrt" process.
Links:
config: https://xenserver.underpants-gnomes.biz … -v2-config
feeds.conf: https://xenserver.underpants-gnomes.biz … feeds.conf
mydiffconfig: https://xenserver.underpants-gnomes.biz … diffconfig
factory: https://xenserver.underpants-gnomes.biz … actory.bin
sysupgrade: https://xenserver.underpants-gnomes.biz … pgrade.bin
(Last edited by johndoe on 30 Jun 2016, 02:07)