It is correct that the file size is always constant. It gets padded with filler values. Similiar question was already asked before: ESP8266 SIFFS.bin file to large. For ESP 32, it’s the same, see code.
The size of the SPIFFS file is is chosen by the selected partition table, as documented. The default SPIFFS size is 0x170000
bytes aka crica 1.5MB.
What exact error is occuring? SPIFFS upload shoult still be perfectly fine with OTA upload selected upload_protocol = espota
and friends, docs)
Yes it did, see code above.