So…I used a variant of this library (Serial) on two Particle Photons — kinda like Arduinos with WiFi. I had trouble whenever I went over about 45 bytes in length of the struct. After hours of frustrating trial and error, I finally stumbled across the fact that the serial buffer is only 64 bytes long. I believe this is the same case on the Arduino. I looked for ways to increase the buffer size, but without any success. Then, I had a bit of an epiphany and decided to drop the baud rate to 1200 baud and…voilà, the darn thing worked with a struct up to about 200 bytes in length. My particular need is to send a char[200] array and I’m now successfully doing that. I also tried the same at 4800 baud without success, but I did have success at 2400 baud.
I don’t know if this solution is good for all, but it addresses my need.