release: v1.6.2 — lift smoke size threshold (3500→3800)

Completes v1.6.1's studio publish. Run 512 shipped v1.6.1 non-studio
(3411 MB) cleanly, but smoke-studio failed the size gate at 3574 MB vs
the 3500 MB threshold. Threshold was set in v1.0.0 pre-agent-browser
(baseline was 3.20 GB local arm64 + 300 MB margin); v1.6.0 baked in
agent-browser + Chromium (+~291 MB net) but the threshold was never
lifted. v1.6.0 never got to smoke because of the network fault, so
nothing surfaced this until v1.6.1's smoke-studio.

Bump SIZE_THRESHOLD_MB to 3800 (~225 MB margin above observed studio
number, tight enough to still catch a genuine +GB regression). Refresh
the comment above the constant with the current baseline + run 512
actuals so future readers know where the number came from.

CI-only change; image bytes identical to v1.6.1 except for the manifest's
release_tag/source_revision. Not base-affecting.

CHANGELOG.md

@@ -15,6 +15,51 @@ Pre-v1.0.0 tags followed the pi npm version (`v{pi_version}[letter]`).
 
 _Nothing yet — next release's changes will accrue here._
 
+## v1.6.2 — 2026-07-23
+
+Patch release. **Completes the v1.6.1 studio publish.** CI-only change; the
+shipped image content is identical to v1.6.1 apart from the bumped `pi`
+version resolution at build time (still `0.81.1`).
+
+> **Note on v1.6.1.** Ran on 2026-07-23; the non-studio variant (`v1.6.1`,
+> `latest`, `base-latest`) shipped cleanly, but the studio variant was blocked
+> in the smoke-studio job by a size assertion that was still calibrated for
+> the pre-`agent-browser` baseline. `v1.6.1-studio` and `latest-studio` were
+> never pushed; `latest-studio` on Hub still points at v1.5.0-studio until
+> v1.6.2 lands. Users who pull `joakimp/pi-devbox:v1.6.1` today get a valid
+> non-studio image with `pi 0.81.1` baked; there is no `v1.6.1-studio` image.
+
+### Fixed (CI)
+
+- **`scripts/smoke-test.sh`: raise `SIZE_THRESHOLD_MB` from `3500` to `3800`.**
+  The 3500 threshold was set in v1.0.0 based on a local arm64 build measured
+  at 3.20 GB plus a `+300 MB` margin. v1.6.0 baked in `agent-browser` +
+  Playwright Chromium (~291 MB net, documented in v1.6.0's entry) but the
+  threshold was never updated — v1.6.0 never ran to smoke because of the
+  site-network fault, so nothing surfaced the miscalibration until
+  run 512 (v1.6.1) reached smoke-studio and reported
+  `3574 MB exceeds threshold 3500 MB`. Actual CI amd64 sizes observed on
+  run 512: **3411 MB non-studio**, **3574 MB studio**. The new 3800 MB
+  ceiling carries ~225 MB margin above the studio number — enough to absorb
+  minor arch/build-cache variance and small future growth, still tight
+  enough to catch a genuine +GB regression. The comment above the constant
+  is refreshed to reflect the new baseline (agent-browser included, run 512
+  actuals). Not base-affecting; base hash unchanged.
+
+- **`scripts/smoke-test.sh`: don't hard-code a `v` prefix on `release_tag`
+  in the `pi-devbox-version` human-output assertion.** (Landed on the
+  retagged `v1.6.1` and carried forward in `v1.6.2`.) The smoke workflow
+  deliberately passes `RELEASE_TAG=smoke` / `RELEASE_TAG=smoke-studio` to
+  the variant build so smoke images don't collide with real `vX.Y.Z` tags,
+  and `pi-devbox-version` correctly prints `pi-devbox smoke`. The prior
+  assertion required the literal substring `pi-devbox v` — only true for
+  real releases — so it fired on every smoke run once it existed. The two
+  neighbouring assertions on `--json` and `--quiet` already cover the value
+  of `release_tag`; the human-output assertion now only verifies that the
+  line renders (substring `pi-devbox ` — note the trailing space). Never
+  fired before because `pi-devbox-version` was added post-v1.5.0 and every
+  CI attempt since was blocked before smoke ran.
+
 ## v1.6.1 — 2026-07-22
 
 Patch release. Headline: **pi `0.80.6` → `0.81.1`** (npm `latest`) — the first

scripts/smoke-test.sh

@@ -31,11 +31,14 @@ IMAGE="${1:?usage: $0 <image>}"
 PASS=0; FAIL=0
 # pi-devbox v1.0.0 (decoupled from opencode-devbox) added pandoc, graphviz,
 # imagemagick, yq, tealdeer, a baked /etc/tmux.conf, and the non-modal
-# editors nano + micro (~15 MB combined). Local arm64 build
+# editors nano + micro (~15 MB combined). v1.6.0 baked in agent-browser +
-# observed 3.20 GB. CI amd64 builds may differ slightly; threshold below
+# Playwright Chromium (~291 MB net after dropping the unused headless-shell
-# carries +300 MB margin to absorb arch differences without false reds.
+# build), which lifted the baseline. CI amd64 actuals observed on run 512
-# Tighten in a follow-up release once amd64 actuals are observed in CI logs.
+# (v1.6.1): 3411 MB non-studio, 3574 MB studio. Threshold below carries
-SIZE_THRESHOLD_MB=3500
+# ~225 MB margin above the studio number to absorb minor arch/build-cache
+# differences and small future growth without false reds, while still
+# catching an unexpected +GB regression.
+SIZE_THRESHOLD_MB=3800
 
 run() {
   local label="$1"; local cmd="$2"