How are you trying to upload the new firmware? From the HSMM-Mesh administration menu? If you're using the "Upload" menu, you need to use the bbhn-1.0.0-brcm.trx file. I believe that .bin files will not work from that menu. .bin files only work from stock firmware or tftp install.
For upgrades from previous HSMM versions to Broadband Hamnet, you need the .trx file.
It's easier to not use the "upload" option at all if you have an intenet connection. Use the "Download Firmware" option.
Connect the router to the internet, go to "setup", select "administration." Select "refresh" under firmware update. Then select bbhn-1.0.0-brcm.trx and then download.
If you're stuck, you can use the tftp install method. In that case you'd use the appropriate .bin file. For a WRT54Gv3.1, it would be bbhn-1.0.0-wrt54g.bin. The TFTP process is described here. There is no ".tgz" file to upgrade to BBHN.
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