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Replace absolute boot gzip ceiling with PR delta gate #4464

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Description

@tyler-dane

Problem

Cloud deploys fail when boot-set gzip grows by a few bytes over the pinned `totalGzipBytes` ceiling in `boot-size-budget.json`. Release v1.3.160 needed an emergency ceiling bump (#4463) instead of shipping product fixes.

Approved direction (Tyler)

  1. Deploy/release path: keep measuring boot gzip when building the web image, log the number, and never fail deploy on absolute bundle size.
  2. PR CI: build merge base and PR head (deploy-shaped config), compute gzip delta, post/update one sticky PR comment (e.g. `Boot bundle: 519.8 KB gzip (+0.4 KB vs main)`).
  3. Gate: fail the PR check only when delta exceeds +5 KB gzip in one PR. Allow override with a `bundle-size-ok` label for intentional growth.
  4. Budget file/docs: simplify `boot-size-budget.json` (drop enforced absolute ceiling; keep informational baseline) and update performance/CI docs.

Acceptance

  • Staging/production web image builds do not exit non-zero on absolute gzip ceiling.
  • Required PR check reports delta vs `main` and enforces +5 KB unless labeled.
  • Docs describe the new model.

Activity

  1. added a commit that references this issue on Oct 14, 2026
    2a7afe8
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