I've followed the path described beautifully by
@mrxyz (thanks!!), and have managed to patch my npc binary so it doesn't drop the frame rate. I've also managed put this together and build a new firmware image which my device happily accepted and upgraded itself to (I'd rather not have a microSD card inserted eventually). This should work without opening up the unit and adding a console connection...
I've got a better/fuller version of busybox working so can run pgrep and reredirect, next steps are to send a MQTT message on doorbell press...
Anyway, happy to share this modified image when I'm done.