The following makes it work
esptool.py --port /dev/tty.wchusbserialfd12240 write_flash -fs 4MB-c1 -fm dio 0x0 espruino_2v04_esp8266_4mb_combined_4096.bin
As I suspected in the http://forum.espruino.com/comments/15179132 it meant that the firmware was actually fine. Just connecting to it has to have the XON/XOFF flow control turned off. I did not even realize something like this was even added and turned on by-default.
XON/XOFF flow control
So the following allows me to connect:
espruino --config SERIAL_FLOW_CONTROL=false --no-ble -b 115200
Thanks for all your hints @MaBe
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