diff --git a/src/update_flash.c b/src/update_flash.c
index 20564b5cd..c09112e43 100644
--- a/src/update_flash.c
+++ b/src/update_flash.c
@@ -361,6 +361,19 @@ static int wolfBoot_delta_update(struct wolfBoot_image *boot,
     #define MAX_UPDATE_SIZE (size_t)((WOLFBOOT_PARTITION_SIZE - (2 *WOLFBOOT_SECTOR_SIZE)))
 #endif
 
+static inline int wolfBoot_get_total_size(struct wolfBoot_image* boot,
+    struct wolfBoot_image* update)
+{
+    uint32_t total_size = 0;
+
+    /* Use biggest size for the swap */
+    total_size = boot->fw_size + IMAGE_HEADER_SIZE;
+    if ((update->fw_size + IMAGE_HEADER_SIZE) > total_size)
+        total_size = update->fw_size + IMAGE_HEADER_SIZE;
+
+    return total_size;
+}
+
 static int RAMFUNCTION wolfBoot_update(int fallback_allowed)
 {
     uint32_t total_size = 0;
@@ -369,6 +382,7 @@ static int RAMFUNCTION wolfBoot_update(int fallback_allowed)
     uint8_t flag, st;
     struct wolfBoot_image boot, update, swap;
     uint16_t update_type;
+    uint32_t fw_size;
 #ifdef EXT_ENCRYPTED
     uint8_t key[ENCRYPT_KEY_SIZE];
     uint8_t nonce[ENCRYPT_NONCE_SIZE];
@@ -385,10 +399,8 @@ static int RAMFUNCTION wolfBoot_update(int fallback_allowed)
     wolfBoot_open_image(&boot, PART_BOOT);
     wolfBoot_open_image(&swap, PART_SWAP);
 
-    /* Use biggest size for the swap */
-    total_size = boot.fw_size + IMAGE_HEADER_SIZE;
-    if ((update.fw_size + IMAGE_HEADER_SIZE) > total_size)
-            total_size = update.fw_size + IMAGE_HEADER_SIZE;
+    /* get total size */
+    total_size = wolfBoot_get_total_size(&boot, &update);
 
     if (total_size <= IMAGE_HEADER_SIZE)
         return -1;
@@ -492,6 +504,25 @@ static int RAMFUNCTION wolfBoot_update(int fallback_allowed)
                 wolfBoot_set_update_sector_flag(sector, flag);
         }
         sector++;
+        /* headers that can be in different positions depending on when the
+         * power fails are now in a known state, re-read and swap fw_size
+         * because the locations are correct but the metadata is now swapped
+         * also recalculate total_size since it could be invalid */
+        if (sector == 1) {
+            wolfBoot_open_image(&boot, PART_BOOT);
+            wolfBoot_open_image(&update, PART_UPDATE);
+
+            /* swap the fw_size since they're now swapped */
+            fw_size = boot.fw_size;
+            boot.fw_size = update.fw_size;
+            update.fw_size = fw_size;
+
+            /* get total size */
+            total_size = wolfBoot_get_total_size(&boot, &update);
+
+            if (total_size <= IMAGE_HEADER_SIZE)
+                return -1;
+        }
     }
     while((sector * sector_size) < WOLFBOOT_PARTITION_SIZE) {
         wb_flash_erase(&boot, sector * sector_size, sector_size);
diff --git a/tools/scripts/sim-update-powerfail-resume.sh b/tools/scripts/sim-update-powerfail-resume.sh
index c3d1b35e6..e3980d03d 100755
--- a/tools/scripts/sim-update-powerfail-resume.sh
+++ b/tools/scripts/sim-update-powerfail-resume.sh
@@ -5,6 +5,7 @@ if [ "x$V" != "x1" ]; then
     exit 1
 fi
 
+./wolfboot.elf powerfail 0 get_version 2>/dev/null
 ./wolfboot.elf powerfail 15000 get_version 2>/dev/null
 ./wolfboot.elf powerfail 18000 get_version 2>/dev/null
 ./wolfboot.elf powerfail 1a000 get_version 2>/dev/null
@@ -15,6 +16,7 @@ if [ "x$V" != "x2" ]; then
     exit 1
 fi
 
+./wolfboot.elf powerfail 1000 get_version 2>/dev/null
 ./wolfboot.elf powerfail 11000 get_version 2>/dev/null
 ./wolfboot.elf powerfail 14000 get_version 2>/dev/null
 ./wolfboot.elf powerfail 1e000 get_version 2>/dev/null
diff --git a/tools/test.mk b/tools/test.mk
index fc8a949a1..441120671 100644
--- a/tools/test.mk
+++ b/tools/test.mk
@@ -920,29 +920,29 @@ test-all: clean
 
 
 test-size-all:
-	make test-size SIGN=NONE LIMIT=4683
+	make test-size SIGN=NONE LIMIT=4722
 	make keysclean
-	make test-size SIGN=ED25519 LIMIT=11350
+	make test-size SIGN=ED25519 LIMIT=11398
 	make keysclean
-	make test-size SIGN=ECC256  LIMIT=22212
+	make test-size SIGN=ECC256  LIMIT=22174
 	make keysclean
-	make test-size SIGN=ECC256 NO_ASM=1 LIMIT=13646
+	make test-size SIGN=ECC256 NO_ASM=1 LIMIT=13610
 	make keysclean
-	make test-size SIGN=RSA2048 LIMIT=11144
+	make test-size SIGN=RSA2048 LIMIT=11182
 	make keysclean
-	make test-size SIGN=RSA2048 NO_ASM=1 LIMIT=11112
+	make test-size SIGN=RSA2048 NO_ASM=1 LIMIT=11162
 	make keysclean
-	make test-size SIGN=RSA4096 LIMIT=11502
+	make test-size SIGN=RSA4096 LIMIT=11546
 	make keysclean
-	make test-size SIGN=RSA4096 NO_ASM=1 LIMIT=11422
+	make test-size SIGN=RSA4096 NO_ASM=1 LIMIT=11462
 	make keysclean
-	make test-size SIGN=ECC384 LIMIT=17550
+	make test-size SIGN=ECC384 LIMIT=17470
 	make keysclean
-	make test-size SIGN=ECC384 NO_ASM=1 LIMIT=15082
+	make test-size SIGN=ECC384 NO_ASM=1 LIMIT=15042
 	make keysclean
-	make test-size SIGN=ED448 LIMIT=13394
+	make test-size SIGN=ED448 LIMIT=13414
 	make keysclean
-	make test-size SIGN=RSA3072 LIMIT=11342
+	make test-size SIGN=RSA3072 LIMIT=11382
 	make keysclean
-	make test-size SIGN=RSA3072 NO_ASM=1 LIMIT=11216
+	make test-size SIGN=RSA3072 NO_ASM=1 LIMIT=11254
 	make keysclean