Fix web flasher versioned releases failing with CORS error

GitHub release download URLs redirect to release-assets.githubusercontent.com
which doesn't return Access-Control-Allow-Origin headers. The browser blocks
cross-origin fetches from the GitHub Pages flasher, causing "Failed to fetch"
for any versioned release while the latest dev build (same-origin) works fine.

Fix: Deploy versioned firmware binaries to GitHub Pages alongside the dev
build at firmware/releases/{tag}/, so all versions are fetched same-origin.
The CI workflow now downloads existing release assets and deploys them to
Pages with keep_files: true to preserve across deploys.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

.github/workflows/release-firmware.yml

@@ -51,6 +51,44 @@ jobs:
           BOOT_APP0=$(find ~/.platformio -name "boot_app0.bin" | head -1)
           cp "$BOOT_APP0" docs/flasher/firmware/
 
+          # For tagged releases, also deploy to a versioned path on GitHub Pages
+          # so the flasher can fetch them same-origin (GitHub release downloads lack CORS)
+          if [[ "$GITHUB_REF" == refs/tags/v* ]]; then
+            TAG="${GITHUB_REF#refs/tags/}"
+            mkdir -p "docs/flasher/firmware/releases/${TAG}"
+            cp .pio/build/tdeck/bootloader.bin "docs/flasher/firmware/releases/${TAG}/"
+            cp .pio/build/tdeck/partitions.bin "docs/flasher/firmware/releases/${TAG}/"
+            cp .pio/build/tdeck/firmware.bin "docs/flasher/firmware/releases/${TAG}/"
+            cp "$BOOT_APP0" "docs/flasher/firmware/releases/${TAG}/"
+          fi
+
+      - name: Download existing release assets for GitHub Pages
+        run: |
+          # Fetch all published releases and download their firmware assets
+          # so versioned firmware is available same-origin on GitHub Pages.
+          # With keep_files: true, each release only needs to be downloaded once.
+          for tag in $(gh api repos/${{ github.repository }}/releases --jq '.[].tag_name'); do
+            dir="docs/flasher/firmware/releases/${tag}"
+            # Skip if we already have this version's firmware (e.g., current tagged build)
+            if [ -f "${dir}/firmware.bin" ]; then
+              echo "Skipping ${tag} — already present"
+              continue
+            fi
+            mkdir -p "${dir}"
+            echo "Downloading assets for ${tag}..."
+            for asset in bootloader.bin partitions.bin boot_app0.bin firmware.bin; do
+              url="https://github.com/${{ github.repository }}/releases/download/${tag}/${asset}"
+              if curl -sL -o "${dir}/${asset}" -w '%{http_code}' "${url}" | grep -q 200; then
+                echo "  ${asset} OK"
+              else
+                rm -f "${dir}/${asset}"
+                echo "  ${asset} not found"
+              fi
+            done
+          done
+        env:
+          GH_TOKEN: ${{ secrets.GITHUB_TOKEN }}
+
       - name: Generate manifest files
         run: |
           VERSION="${{ steps.version.outputs.VERSION }}"
@@ -94,6 +132,7 @@ jobs:
           github_token: ${{ secrets.GITHUB_TOKEN }}
           publish_dir: ./docs/flasher
           destination_dir: flasher
+          keep_files: true
 
       - name: Create GitHub Release
         if: startsWith(github.ref, 'refs/tags/v')

docs/flasher/index.html

@@ -386,7 +386,7 @@
                     const hasAll = REQUIRED_FULL_ASSETS.every(f => assetNames.includes(f));
                     option.value = release.tag_name;
                     option.textContent = release.tag_name + (release.name && release.name !== release.tag_name ? ` — ${release.name}` : '');
-                    option.dataset.downloadUrl = `https://github.com/torlando-tech/pyxis/releases/download/${release.tag_name}/`;
+                    option.dataset.downloadUrl = `firmware/releases/${release.tag_name}/`;
                     option.dataset.hasFullAssets = hasAll ? 'true' : 'false';
                     versionSelect.appendChild(option);
                 }
@@ -458,7 +458,7 @@
                 for (const file of files) {
                     log(`Loading ${file.name}...`);
                     const response = await fetch(file.path);
-                    if (!response.ok) throw new Error(`Failed to load ${file.name}`);
+                    if (!response.ok) throw new Error(`Failed to fetch ${file.name} (HTTP ${response.status}). This version may not be available yet — try "Latest" instead.`);
                     const arrayBuffer = await response.arrayBuffer();
                     const bytes = new Uint8Array(arrayBuffer);
                     let binaryString = '';