Add additional test coverage for monolithic self updates with asymmetric partition sizing

.github/workflows/test-sim-self-update.yml

@@ -38,6 +38,28 @@ jobs:
           cp config/examples/sim-self-update-monolithic.config .config
           make test-sim-self-update-monolithic
 
+      # Shrink BOOT below the payload size so staging only works because the
+      # UPDATE partition is sized independently (WOLFBOOT_PARTITION_UPDATE_SIZE)
+      - name: Run monolithic self-update test (payload exceeds a BOOT-sized slot)
+        run: |
+          make clean
+          cp config/examples/sim-self-update-monolithic.config .config
+          make test-sim-self-update-monolithic WOLFBOOT_PARTITION_SIZE=0x30000 WOLFBOOT_PARTITION_UPDATE_ADDRESS=0x50000
+
+      # Unset WOLFBOOT_PARTITION_UPDATE_SIZE so it falls back to
+      # WOLFBOOT_PARTITION_SIZE, restoring the legacy symmetric layout
+      - name: Run monolithic self-update test (legacy symmetric layout)
+        run: |
+          make clean
+          cp config/examples/sim-self-update-monolithic.config .config
+          make test-sim-self-update-monolithic WOLFBOOT_PARTITION_SIZE=0x80000 WOLFBOOT_PARTITION_UPDATE_SIZE= WOLFBOOT_PARTITION_UPDATE_ADDRESS=0xA0000
+
+      - name: Run monolithic self-update oversize rejection test
+        run: |
+          make clean
+          cp config/examples/sim-self-update-monolithic.config .config
+          make test-sim-self-update-monolithic-oversize
+
       - name: Run self-header verification test (internal flash)
         run: |
           make clean
@@ -50,6 +72,9 @@ jobs:
           cp config/examples/sim-self-header-ext.config .config
           make test-sim-self-header-ext-verify
 
+      # With WOLFBOOT_SELF_HEADER=1 the app grows enough that the payload
+      # exceeds what a BOOT-sized slot could stage, so this step also covers
+      # asymmetric staging capacity
       - name: Run combined monolithic self-update + self-header test
         run: |
           make clean

docs/firmware_update.md

@@ -386,6 +386,10 @@ make clean && make
 make test-sim-self-update-monolithic
 ```
 
+A companion negative test, `test-sim-self-update-monolithic-oversize`, stages a
+signed payload larger than the install span and verifies that wolfBoot refuses
+it without touching the bootloader or the BOOT partition.
+
 #### Skipping boot image verification
 
 When wolfBoot is used together with the [self-header](#self-header-persisting-the-bootloader-manifest)

tools/test.mk

@@ -343,6 +343,49 @@ test-sim-self-update-monolithic-self-header: wolfboot.bin test-app/image_v1_sign
 	@echo "  Self-header persisted correctly: PASSED"
 	@echo "=== Monolithic Self-Update + Self-Header Test PASSED ==="
 
+# Test that an oversized monolithic self-update is rejected. The payload is
+# signed and staged normally, but its firmware size exceeds the install span
+# (bootloader region + BOOT partition minus the trailer sector), so wolfBoot
+# must refuse it and leave the bootloader and BOOT partition untouched.
+# Requires a build with wolfBoot_printf output (e.g. DEBUG=1, as in the
+# sim-self-update-monolithic example config).
+test-sim-self-update-monolithic-oversize: wolfboot.bin test-app/image_v1_signed.bin FORCE
+	@echo "=== Simulator Monolithic Self-Update Oversize Rejection Test ==="
+	@# Create dummy bootloader (0xAA pattern, exactly bootloader region size)
+	$(Q)dd if=/dev/zero bs=$$(($(WOLFBOOT_PARTITION_BOOT_ADDRESS) - $(ARCH_FLASH_OFFSET))) count=1 2>/dev/null | tr '\000' '\252' > monolithic_dummy_bl.bin
+	@# Build a payload 0x100 bytes past the max install span, padded with 0xFF.
+	@# It still fits the UPDATE partition, so only the install-span check can
+	@# reject it.
+	$(Q)dd if=/dev/zero bs=$$(($(WOLFBOOT_PARTITION_BOOT_ADDRESS) - $(ARCH_FLASH_OFFSET) + $(WOLFBOOT_PARTITION_SIZE) - $(WOLFBOOT_SECTOR_SIZE) + 0x100)) count=1 2>/dev/null | tr '\000' '\377' > monolithic_oversize.bin
+	$(Q)cat monolithic_dummy_bl.bin test-app/image_v1_signed.bin | dd of=monolithic_oversize.bin conv=notrunc 2>/dev/null
+	@# Sign with an inflated update partition size: the keytool refuses
+	@# oversized images, and the point here is the bootloader's own guard
+	$(Q)$(SIGN_ENV) WOLFBOOT_PARTITION_UPDATE_SIZE=0x1000000 $(SIGN_TOOL) $(SIGN_OPTIONS) --wolfboot-update monolithic_oversize.bin $(PRIVATE_KEY) 2
+	@# Create update partition with signed oversized image and "pBOOT" trailer
+	$(Q)dd if=/dev/zero bs=$$(($(or $(WOLFBOOT_PARTITION_UPDATE_SIZE),$(WOLFBOOT_PARTITION_SIZE)))) count=1 2>/dev/null | tr '\000' '\377' > update_part.dd
+	$(Q)dd if=monolithic_oversize_v2_signed.bin of=update_part.dd bs=1 conv=notrunc
+	$(Q)printf "pBOOT" | dd of=update_part.dd bs=1 seek=$$(($(or $(WOLFBOOT_PARTITION_UPDATE_SIZE),$(WOLFBOOT_PARTITION_SIZE)) - 5)) conv=notrunc
+	@# Create erased boot partition
+	$(Q)dd if=/dev/zero bs=$$(($(WOLFBOOT_PARTITION_SIZE))) count=1 2>/dev/null | tr '\000' '\377' > boot_part.dd
+	@# Assemble flash: wolfboot.bin at 0, empty boot partition, update partition
+	$(Q)$(BINASSEMBLE) internal_flash.dd \
+		0 wolfboot.bin \
+		$$(($(WOLFBOOT_PARTITION_BOOT_ADDRESS) - $(ARCH_FLASH_OFFSET))) boot_part.dd \
+		$$(($(WOLFBOOT_PARTITION_UPDATE_ADDRESS) - $(ARCH_FLASH_OFFSET))) update_part.dd
+	@# Run simulator - the self-update must be refused before any flash write
+	$(Q)./wolfboot.elf get_version > monolithic_oversize.log 2>&1 || true
+	$(Q)grep -q "Self update image too large" monolithic_oversize.log || \
+		{ echo "Rejection message not found; simulator output:"; \
+		  cat monolithic_oversize.log; false; }
+	@echo "  Oversized self-update rejected: PASSED"
+	@# Verify the bootloader region still contains the original wolfboot.bin
+	$(Q)cmp -n $$(wc -c < wolfboot.bin | awk '{print $$1}') wolfboot.bin internal_flash.dd
+	@echo "  Bootloader region untouched: PASSED"
+	@# Verify the boot partition is still fully erased
+	$(Q)cmp -n $$(($(WOLFBOOT_PARTITION_SIZE))) boot_part.dd internal_flash.dd 0 $$(($(WOLFBOOT_PARTITION_BOOT_ADDRESS) - $(ARCH_FLASH_OFFSET)))
+	@echo "  Boot partition untouched: PASSED"
+	@echo "=== Monolithic Self-Update Oversize Rejection Test PASSED ==="
+
 # Test self-header cryptographic verification (hash + signature validation)
 #
 # Verifies that an application can cryptographically verify the bootloader using