Hi Ryan (@AORPLS ),
The “Board ADC ID (mV): 2541 Identified variant: Unknown” failure is caused by this piece of code. It has nothing to do with the file system filling up.
It’s unlikely to be the 3.3K and 10K ID resistors as they are 1% parts. It is almost certainly the calibration on the ESP32’s ADC. It’s rare, but on some parts the ADC millivolt values can be off. It should be reading 2481mV, but, in your case, is reading 2541mV.
A return is probably going to be the best solution for you. It is possible to fix this in hardware or software, but neither is easy.
Apologies for the hassle,
Paul