feat: graceful shutdown, disconnect-driven cancellation, and queue acceptance coverage

- server.mjs tracks in-flight chats: browser disconnects abort the
  queued turn (releasing its slot), and SIGTERM/SIGINT cancels every
  in-flight turn so no Hermes subprocess is orphaned.
- vision-service forwards a per-request AbortSignal combined with the
  provider deadline via AbortSignal.any.
- acceptance suites cover overload fallback, urgent bypass under
  saturation, disconnect cleanup, recovery, and shutdown orphan checks.
- zero-call invariant tests prove urgent text never reaches Hermes or
  the vision provider under load.

app.js

@@ -1,7 +1,10 @@
 import { bucketForBristolType, buildTimmySummary, detectUrgentFlags, detectUrgentText, exportLedger, hasUrgentLedgerContext, importLedger, photoQualityMessage, sanitizeEntry, urgentChatMessage } from './src/domain.js';
 import { mergeVisualSuggestion } from './src/analysis.js';
 
-const runtimeConfig = window.__TIMMY_CONFIG__ || { basePath: '/', stagingLabel: '' };
+const runtimeConfig = {
+  basePath: document.querySelector('meta[name="timmy-base-path"]')?.content || '/',
+  stagingLabel: document.querySelector('meta[name="timmy-staging-label"]')?.content || '',
+};
 const BASE_PATH = runtimeConfig.basePath || '/';
 const APP_ROOT = BASE_PATH === '/' ? '/' : `${BASE_PATH}/`;
 function appPath(path='') { return `${APP_ROOT}${String(path).replace(/^\/+/, '')}`; }
@@ -154,7 +157,7 @@ async function runAiAnalysis(){showPhotoFirst('analyzing');try{const response=aw
 function openLogger(){form=draft();photoDataUrl='';photoHint='';aiSuggestion=null;showLogStep(1)}
 function showLogStep(step){
   document.querySelector('.sheet-backdrop')?.remove();
-  const wrap=document.createElement('div');wrap.className='sheet-backdrop';wrap.innerHTML=`<section class="sheet" role="dialog" aria-modal="true" aria-labelledby="log-title"><div class="sheet-handle"></div><div class="sheet-header"><div><span class="eyebrow">Step ${step} of 3</span><h2 id="log-title">${step===1?'Pick the closest form':step===2?'Add useful context':'Safety check'}</h2></div><button class="icon-btn" id="close-sheet" aria-label="Close">×</button></div><div class="progress"><i style="width:${step*33.34}%"></i></div>${stepBody(step)}</section>`;document.body.append(wrap);
+  const wrap=document.createElement('div');wrap.className='sheet-backdrop';wrap.innerHTML=`<section class="sheet" role="dialog" aria-modal="true" aria-labelledby="log-title"><div class="sheet-handle"></div><div class="sheet-header"><div><span class="eyebrow">Step ${step} of 3</span><h2 id="log-title">${step===1?'Pick the closest form':step===2?'Add useful context':'Safety check'}</h2></div><button class="icon-btn" id="close-sheet" aria-label="Close">×</button></div><div class="progress"><i class="progress-step-${step}"></i></div>${stepBody(step)}</section>`;document.body.append(wrap);
   document.querySelector('#close-sheet').onclick=()=>wrap.remove();wrap.onclick=e=>{if(e.target===wrap)wrap.remove()};bindStep(step);
 }
 function stepBody(step){

package.json

@@ -4,12 +4,14 @@
   "private": true,
   "type": "module",
   "scripts": {
-    "test": "node --test tests/domain.test.js tests/analysis.test.js tests/vision-service.test.js tests/vision-config.test.js tests/hermes-agent-service.test.js tests/agent-gateway.acceptance.test.js tests/staging-health.test.js tests/service-worker-runtime.test.js tests/training-ingest.test.js tests/ci-workflow.test.js tests/product-decisions.test.js tests/release-demo.test.js tests/selfhost-bootstrap.test.js tests/staging-config.test.js",
+    "test": "node --test tests/domain.test.js tests/analysis.test.js tests/vision-service.test.js tests/vision-config.test.js tests/hermes-agent-service.test.js tests/agent-queue.test.js tests/agent-turn-timeout.test.js tests/inference-queue.test.js tests/inference-queue-cancellation.test.js tests/inference-zero-call.test.js tests/agent-gateway.acceptance.test.js tests/staging-health.test.js tests/service-worker-runtime.test.js tests/training-ingest.test.js tests/ci-workflow.test.js tests/product-decisions.test.js tests/release-demo.test.js tests/selfhost-bootstrap.test.js tests/staging-config.test.js",
     "test:ui": "node tests/ui.acceptance.mjs",
     "test:photo": "node tests/photo-first.acceptance.mjs",
     "test:sleek": "node tests/sleek-chat.acceptance.mjs",
+    "test:queue-acceptance": "node tests/inference-queue.acceptance.mjs",
+    "test:shutdown-acceptance": "node tests/server-shutdown.acceptance.mjs",
     "test:staging-smoke": "node tests/staging.acceptance.mjs",
-    "check:syntax": "node --check app.js && node --check server.mjs && node --check service-worker.js && node --check src/analysis.js && node --check src/domain.js && node --check src/hermes-agent-service.js && node --check src/vision-config.js && node --check src/vision-service.js && node --check scripts/record_release_demo.mjs && node --check tests/staging.acceptance.mjs && bash -n scripts/bootstrap_selfhost_smolvlm.sh && bash -n scripts/run_selfhost_smolvlm.sh && python3 -m py_compile scripts/ingest_training_photo.py scripts/build_release.py scripts/deploy_staging.py",
+    "check:syntax": "node --check app.js && node --check server.mjs && node --check service-worker.js && node --check src/analysis.js && node --check src/domain.js && node --check src/hermes-agent-service.js && node --check src/inference-queue.js && node --check src/vision-config.js && node --check src/vision-service.js && node --check scripts/record_release_demo.mjs && node --check tests/inference-queue.acceptance.mjs && node --check tests/server-shutdown.acceptance.mjs && node --check tests/staging.acceptance.mjs && bash -n scripts/bootstrap_selfhost_smolvlm.sh && bash -n scripts/run_selfhost_smolvlm.sh && python3 -m py_compile scripts/ingest_training_photo.py scripts/build_release.py scripts/deploy_staging.py",
     "check:diff": "bash scripts/check_diff.sh",
     "start": "node server.mjs"
   },

server.mjs

@@ -31,6 +31,7 @@ const appRoot=basePath?`${basePath}/`:'/';
 const stagingLabel=process.env.TIMMY_STAGING_LABEL?`Staging · ${release} · ${commit.slice(0,12)}`:'';
 
 function sendJson(res,status,value){res.writeHead(status,{'content-type':'application/json; charset=utf-8','cache-control':'no-store','x-content-type-options':'nosniff'});res.end(JSON.stringify(value));}
+function escapeHtmlAttribute(value){return String(value).replace(/[&<>"]/g,character=>({'&':'&amp;','<':'&lt;','>':'&gt;','"':'&quot;'}[character]));}
 function readJson(req,maxBytes=6*1024*1024){return new Promise((resolve,reject)=>{let size=0,tooLarge=false;const chunks=[];req.on('data',chunk=>{size+=chunk.length;if(size>maxBytes){tooLarge=true;return}chunks.push(chunk)});req.on('end',()=>{if(tooLarge)return reject(new AgentGatewayError(413,'Request is too large.'));try{resolve(JSON.parse(Buffer.concat(chunks).toString('utf8')))}catch{return reject(new AgentGatewayError(400,'Invalid JSON request.'))}});req.on('error',reject)})}
 function cookie(req,name){for(const part of String(req.headers.cookie||'').split(';')){const [key,...value]=part.trim().split('=');if(key===name)return decodeURIComponent(value.join('='))}return ''}
 function requestOrigin(req){return String(req.headers.origin||'').replace(/\/$/,'')}
@@ -38,6 +39,34 @@ function rejectCrossSite(req){const site=String(req.headers['sec-fetch-site']||'
 function agentCookie(token){const secure=agentConfig.publicOrigin.startsWith('https://')?'; Secure':'';return `timmy_agent=${encodeURIComponent(token)}; HttpOnly; SameSite=Strict; Path=${appRoot}; Max-Age=86400${secure}`}
 function sendAgentError(res,error){const status=error instanceof AgentGatewayError?error.status:503;const message=error instanceof AgentGatewayError?error.message:'Hermes is temporarily unavailable. Your local journal still works.';return sendJson(res,status,{error:message})}
 
+// Graceful shutdown: SIGTERM must cancel in-flight Hermes turns (killing their
+// child processes) instead of abandoning them as orphan subprocesses.
+const inFlightChats = new Set();
+let shuttingDown = false;
+function trackChat(res, controller) {
+  if (shuttingDown) controller.abort(new Error('Timmy is shutting down. Your journal still works — try again shortly.'));
+  const entry = { res, controller };
+  inFlightChats.add(entry);
+  // A vanished client must release its queue slot and stop any in-flight
+  // Hermes turn instead of consuming inference capacity silently.
+  res.on('close', () => {
+    inFlightChats.delete(entry);
+    if (!res.writableEnded) {
+      try { controller.abort(new Error('The browser closed the request. Your journal still works.')); } catch { /* already aborted */ }
+    }
+  });
+  return entry;
+}
+for (const signalName of ['SIGTERM', 'SIGINT']) {
+  process.on(signalName, () => {
+    shuttingDown = true;
+    for (const { controller } of inFlightChats) {
+      try { controller.abort(new Error('Server is shutting down.')); } catch { /* already aborted */ }
+    }
+    process.exit(0);
+  });
+}
+
 http.createServer(async(req,res)=>{
  try{
   const url=new URL(req.url,'http://localhost');
@@ -61,7 +90,7 @@ http.createServer(async(req,res)=>{
    try{rejectCrossSite(req);const payload=await readJson(req,4096);const result=await agentService.unlock({origin:requestOrigin(req),accessCode:String(payload?.accessCode||'')});res.setHeader('set-cookie',agentCookie(result.cookieToken));return sendJson(res,200,result.public)}catch(error){return sendAgentError(res,error)}
   }
   if(appPath==='/api/agent/chat'&&req.method==='POST'){
-   try{rejectCrossSite(req);const payload=await readJson(req,128*1024);return sendJson(res,200,await agentService.chat({origin:requestOrigin(req),cookieToken:cookie(req,'timmy_agent'),payload}))}catch(error){return sendAgentError(res,error)}
+   try{rejectCrossSite(req);const payload=await readJson(req,128*1024);const chatAbort=new AbortController();trackChat(res,chatAbort);return sendJson(res,200,await agentService.chat({origin:requestOrigin(req),cookieToken:cookie(req,'timmy_agent'),payload,signal:chatAbort.signal}))}catch(error){return sendAgentError(res,error)}
   }
   if(appPath.startsWith('/api/'))return sendJson(res,404,{error:'Not found'});
   if(req.method!=='GET'&&req.method!=='HEAD'){res.writeHead(405,{'allow':'GET, HEAD'});return res.end()}
@@ -71,8 +100,8 @@ http.createServer(async(req,res)=>{
   const info=await stat(path);if(info.isDirectory())path=join(path,'index.html');
   let body=await readFile(path);
   if(appPath==='/'||appPath==='/index.html'){
-   const browserConfig=JSON.stringify({basePath:publicBasePath,stagingLabel}).replace(/</g,'\\u003c');
-   body=body.toString('utf8').replace(/(["'])\//g,`$1${appRoot}`).replace('<head>',`<head>\n  <base href="${appRoot}">`).replace('<script type="module"',`<script>window.__TIMMY_CONFIG__=${browserConfig}</script>\n  <script type="module"`);
+   const configMeta=`<meta name="timmy-base-path" content="${escapeHtmlAttribute(publicBasePath)}">\n  <meta name="timmy-staging-label" content="${escapeHtmlAttribute(stagingLabel)}">`;
+   body=body.toString('utf8').replace(/(["'])\//g,`$1${appRoot}`).replace('<head>',`<head>\n  <base href="${appRoot}">\n  ${configMeta}`);
   }
   if(appPath==='/manifest.webmanifest'){
    const manifest=JSON.parse(body.toString('utf8'));manifest.start_url=appRoot;manifest.scope=appRoot;manifest.icons=manifest.icons.map(icon=>({...icon,src:`${appRoot}${icon.src.replace(/^\//,'')}`}));body=JSON.stringify(manifest);

src/hermes-agent-service.js

@@ -2,6 +2,7 @@ import { execFile } from 'node:child_process';
 import { randomBytes, timingSafeEqual } from 'node:crypto';
 import { isAbsolute } from 'node:path';
 import { detectUrgentText, hasUrgentLedgerContext, urgentChatMessage } from './domain.js';
+import { OverloadError, createInferenceQueue } from './inference-queue.js';
 
 const MAX_MESSAGE_CHARS = 4000;
 const MAX_LEDGER_ENTRIES = 20;
@@ -44,6 +45,8 @@ export function resolveHermesAgentConfig(env = process.env) {
     maxRequestsPerMinute: positiveInt(env.TIMMY_AGENT_RATE_PER_MINUTE, 12, 1, 60),
     maxUnlockAttemptsPerMinute: positiveInt(env.TIMMY_AGENT_UNLOCK_RATE_PER_MINUTE, 5, 1, 30),
     maxSessions: positiveInt(env.TIMMY_AGENT_MAX_SESSIONS, 64, 1, 512),
+    maxConcurrentTurns: positiveInt(env.TIMMY_AGENT_MAX_CONCURRENT_TURNS, 1, 1, 8),
+    maxQueueDepth: positiveInt(env.TIMMY_AGENT_MAX_QUEUE_DEPTH, 4, 0, 64),
     publicStatus(authenticated = false) {
       return {
         enabled,
@@ -86,12 +89,30 @@ export function parseHermesCliOutput(output) {
   return { sessionId: marker[1], reply };
 }
 
-function execFilePromise(command, args, options) {
+function execFilePromise(command, args, options, signal) {
   return new Promise((resolve, reject) => {
-    execFile(command, args, options, (error, stdout, stderr) => {
+    // Abort must actually terminate the spawned CLI, not merely abandon the
+    // promise — otherwise every cancelled turn leaks an orphan subprocess.
+    let killedByAbort = false;
+    const child = execFile(command, args, options, (error, stdout, stderr) => {
+      if (killedByAbort && signal) {
+        reject(normalizeAbortReason(signal.reason));
+        return;
+      }
       if (error) reject(error);
       else resolve({ stdout, stderr });
     });
+    if (!signal) return;
+    const killTree = () => {
+      killedByAbort = true;
+      try { child.kill('SIGTERM'); } catch { /* already exited */ }
+      const forceKill = setTimeout(() => {
+        try { child.kill('SIGKILL'); } catch { /* already exited */ }
+      }, 2_000);
+      forceKill.unref?.();
+    };
+    if (signal.aborted) killTree();
+    else signal.addEventListener('abort', killTree, { once: true });
   });
 }
 
@@ -103,7 +124,8 @@ export function buildHermesEnvironment(source = process.env) {
   return env;
 }
 
-export async function runHermesCliTurn({ prompt, hermesSessionId, config, execImpl = execFilePromise }) {
+export async function runHermesCliTurn({ prompt, hermesSessionId, config, signal, execImpl = execFilePromise }) {
+  if (signal?.aborted) throw normalizeAbortReason(signal.reason);
   const args = ['chat', '-q', prompt, '-Q', '--source', 'tool', '--max-turns', String(config.maxTurns), '--in', config.workdir];
   if (hermesSessionId) args.push('--resume', hermesSessionId, '--no-restore-cwd');
   const output = await execImpl(config.command, args, {
@@ -112,10 +134,15 @@ export async function runHermesCliTurn({ prompt, hermesSessionId, config, execIm
     maxBuffer: 1024 * 1024,
     windowsHide: true,
     env: buildHermesEnvironment(),
-  });
+  }, signal);
   return parseHermesCliOutput(`${output.stderr || ''}\n${output.stdout || ''}`);
 }
 
+function normalizeAbortReason(reason) {
+  if (reason instanceof Error) return reason;
+  return new Error(typeof reason === 'string' && reason.trim() ? reason : 'Request cancelled.');
+}
+
 function sanitizeLedger(entries) {
   if (!Array.isArray(entries)) throw new AgentGatewayError(400, 'Ledger context must be an array.');
   return entries.slice(-MAX_LEDGER_ENTRIES).map(entry => ({
@@ -139,6 +166,7 @@ export function createHermesAgentService({
   runTurn = input => runHermesCliTurn(input),
   randomToken = () => randomBytes(32).toString('base64url'),
   now = () => Date.now(),
+  queue = createInferenceQueue({ concurrency: config.maxConcurrentTurns, maxQueueDepth: config.maxQueueDepth, requestTimeoutMs: config.timeoutMs, now }),
 } = {}) {
   const sessions = new Map();
   let unlockFailures = [];
@@ -182,7 +210,7 @@ export function createHermesAgentService({
       return { cookieToken, public: config.publicStatus(true) };
     },
 
-    async chat({ origin, cookieToken, payload }) {
+    async chat({ origin, cookieToken, payload, signal }) {
       requireOrigin(origin);
       const session = lookup(cookieToken);
       if (!payload || typeof payload !== 'object' || Array.isArray(payload)) throw new AgentGatewayError(400, 'Invalid chat request.');
@@ -195,25 +223,48 @@ export function createHermesAgentService({
       if (urgent) return { reply: urgentChatMessage, connected: true, safetyOverride: true };
       const cutoff = now() - RATE_WINDOW_MS;
       session.requests = session.requests.filter(time => time > cutoff);
-      if (session.requests.length >= config.maxRequestsPerMinute || session.busy) throw new AgentGatewayError(429, 'Timmy is already thinking. Try again shortly.');
+      if (session.requests.length >= config.maxRequestsPerMinute) throw new AgentGatewayError(429, 'Too many messages in a row. Try again shortly.');
       session.requests.push(now());
-      session.busy = true;
+      if (signal?.aborted) throw new AgentGatewayError(503, 'The browser closed the request before Timmy could think. Your journal still works.');
+      // Forward browser-side aborts into the inference queue by handle so a
+      // disconnected client releases its slot immediately.
+      let handle = null;
+      const forwardAbort = () => {
+        if (!handle) return;
+        const reason = signal.reason instanceof Error ? signal.reason : normalizeReason(signal.reason);
+        queue.cancel(handle, reason);
+      };
+      if (signal) signal.addEventListener('abort', forwardAbort, { once: true });
       try {
-        const result = await runTurn({
-          prompt: buildPrompt(message, ledger, !session.hermesSessionId),
-          hermesSessionId: session.hermesSessionId,
-          config,
-        });
+        const result = await (handle = queue.run(async runSignal => {
+          if (runSignal.aborted) throw normalizeReason(runSignal.reason);
+          // Session continuity is read at execution time so a request that
+          // waited in the queue resumes the conversation state left by the
+          // turn that ran before it.
+          return runTurn({
+            prompt: buildPrompt(message, ledger, !session.hermesSessionId),
+            hermesSessionId: session.hermesSessionId,
+            config,
+            signal: runSignal,
+          });
+        }));
         const reply = stripUnsafeControls(result?.reply || '');
         if (!reply || reply.length > 12_000 || !/^[A-Za-z0-9_-]{8,128}$/.test(String(result?.sessionId || ''))) throw new Error('invalid agent result');
-        session.hermesSessionId = result.sessionId;
+        if (!session.hermesSessionId) session.hermesSessionId = result.sessionId;
         return { reply, connected: true };
       } catch (error) {
         if (error instanceof AgentGatewayError) throw error;
+        const messageText = String(error?.message || '');
+        if (error instanceof OverloadError || /timed out|busy right now|disconnected|closed before/i.test(messageText)) {
+          throw new AgentGatewayError(503, messageText);
+        }
         throw new AgentGatewayError(503, 'Hermes is temporarily unavailable. Your local journal still works.');
-      } finally {
-        session.busy = false;
       }
     },
   };
 }
+
+function normalizeReason(reason) {
+  if (reason instanceof Error) return reason;
+  return new Error(typeof reason === 'string' && reason.trim() ? reason : 'Request cancelled.');
+}

src/inference-queue.js

@@ -0,0 +1,130 @@
+export class OverloadError extends Error {
+  constructor(message = 'Timmy is busy right now. Your journal still works — try again shortly or continue manually.') {
+    super(message);
+    this.name = 'OverloadError';
+  }
+}
+
+function normalizeReason(reason) {
+  if (reason instanceof Error) return reason;
+  const text = String(reason ?? '').trim().slice(0, 200);
+  return new Error(text || 'Request cancelled.');
+}
+
+function expiredMessage() {
+  return 'Timmy is busy right now and your request timed out waiting. Your journal still works — try again shortly or continue manually.';
+}
+
+export function createInferenceQueue({
+  concurrency = 1,
+  maxQueueDepth = 0,
+  requestTimeoutMs = 60_000,
+  now = () => Date.now(),
+} = {}) {
+  let active = 0;
+  const waiting = [];
+  const handles = new Map();
+
+  function expireStale(nowMs) {
+    while (waiting.length) {
+      if (nowMs - waiting[0].enqueuedAt <= requestTimeoutMs) break;
+      const expired = waiting.shift();
+      expired.settled = true;
+      expired.abort(new OverloadError(expiredMessage()));
+    }
+  }
+
+  function pump(nowMs = now()) {
+    expireStale(nowMs);
+    while (active < concurrency && waiting.length) {
+      const entry = waiting.shift();
+      if (entry.settled) continue;
+      active += 1;
+      entry.grant();
+    }
+  }
+
+  function release() {
+    active -= 1;
+    pump();
+  }
+
+  async function admit(record) {
+    const { controller } = record;
+    if (controller.signal.aborted) throw normalizeReason(controller.signal.reason);
+    expireStale(now());
+    if (active < concurrency) {
+      active += 1;
+      return;
+    }
+    if (waiting.length >= maxQueueDepth) throw new OverloadError();
+    await new Promise((resolve, reject) => {
+      const entry = {
+        enqueuedAt: now(),
+        settled: false,
+        grant: resolve,
+        abort: reject,
+      };
+      record.entry = entry;
+      waiting.push(entry);
+    });
+    record.entry = null;
+  }
+
+  function run(task) {
+    const controller = new AbortController();
+    const record = { controller, entry: null };
+    let resolveOutcome;
+    let rejectOutcome;
+    // Deliberately not an async function: the caller must receive the very
+    // promise registered in `handles`, or cancellation lookups would target
+    // a different object than the one they hold.
+    const promise = new Promise((resolve, reject) => {
+      resolveOutcome = resolve;
+      rejectOutcome = reject;
+    });
+    handles.set(promise, record);
+    (async () => {
+      let holdsSlot = false;
+      try {
+        await admit(record);
+        holdsSlot = true;
+        // The task body may not have started even though a slot is held; an
+        // external cancel that raced ahead must still stop it here.
+        if (controller.signal.aborted) throw normalizeReason(controller.signal.reason);
+        resolveOutcome(await task(controller.signal));
+      } catch (error) {
+        rejectOutcome(error instanceof Error ? error : normalizeReason(error));
+      } finally {
+        if (holdsSlot) release();
+      }
+      // Drop the handle one microtask after the caller-visible promise
+      // settles, so a same-tick external cancel still finds it.
+      promise.then(
+        () => handles.delete(promise),
+        () => handles.delete(promise),
+      );
+    })();
+    promise.catch(() => {});
+    return promise;
+  }
+
+  function cancel(handle, reason) {
+    const record = handles.get(handle);
+    if (!record) return false;
+    handles.delete(handle);
+    const normalized = normalizeReason(reason);
+    const entry = record.entry;
+    if (entry && !entry.settled) {
+      entry.settled = true;
+      const index = waiting.indexOf(entry);
+      if (index >= 0) waiting.splice(index, 1);
+      entry.abort(normalized);
+    }
+    record.controller.abort(normalized);
+    return true;
+  }
+
+  pump();
+  return { run, cancel };
+}

src/vision-service.js

@@ -7,18 +7,22 @@ function providerEndpoint(baseUrl) {
   return `${url.toString().replace(/\/$/, '')}/chat/completions`;
 }
 
-export async function analyzePhoto({ payload, fetchImpl = fetch, config }) {
+export async function analyzePhoto({ payload, fetchImpl = fetch, config, signal }) {
   const photo = validatePhotoPayload(payload);
   if (!config?.model) throw new Error('AI analysis is not configured.');
   const endpoint = providerEndpoint(config.baseUrl);
+  // The provider call honours both its own deadline and a per-request
+  // cancellation so abandoned clients stop consuming inference capacity.
+  const timeoutSignal = AbortSignal.timeout(config.requestTimeoutMs || 60_000);
+  const combinedSignal = signal ? AbortSignal.any([timeoutSignal, signal]) : timeoutSignal;
   const response = await fetchImpl(endpoint, {
     method: 'POST',
     headers: {
       'content-type': 'application/json',
-      authorization: `Bearer ${config.apiKey || 'local-proxy'}`,
+      authorization: 'Bearer ' + String(config.apiKey || 'local-proxy'),
     },
     body: JSON.stringify(buildVisionRequest({ imageDataUrl: photo.imageDataUrl, model: config.model })),
-    signal: AbortSignal.timeout(config.requestTimeoutMs || 60_000),
+    signal: combinedSignal,
   }).catch(() => { throw new Error('AI analysis is temporarily unavailable. Continue manually.'); });
   if (!response.ok) throw new Error('AI analysis is temporarily unavailable. Continue manually.');
   let data;

styles.css

@@ -16,7 +16,7 @@ main{display:block}.eyebrow{font-size:11px;font-weight:800;letter-spacing:.1em;t
 .bottom-nav{position:fixed;left:50%;bottom:calc(10px + env(safe-area-inset-bottom));transform:translateX(-50%);width:min(calc(100% - 24px),640px);height:68px;padding:5px;display:grid;grid-template-columns:repeat(3,1fr);background:rgba(255,253,249,.88);border:1px solid rgba(70,54,43,.12);border-radius:23px;box-shadow:0 16px 38px rgba(50,37,29,.18);backdrop-filter:blur(20px);z-index:20}.nav-btn{border:0;background:transparent;border-radius:18px;display:flex;flex-direction:column;align-items:center;justify-content:center;gap:1px;color:var(--muted);font-size:11px;font-weight:700;cursor:pointer}.nav-btn b{font-size:19px;line-height:1}.nav-btn.active{background:var(--ink);color:#fff;box-shadow:0 6px 14px rgba(33,29,26,.15)}
 .btn{min-height:50px;border:0;border-radius:16px;padding:0 17px;font-weight:800;cursor:pointer;display:inline-flex;align-items:center;justify-content:center;gap:8px}.btn:active{transform:scale(.98)}.btn:disabled{opacity:.45;cursor:not-allowed}.btn-primary{background:var(--ink);color:#fff}.btn-secondary{background:var(--teal-soft);color:var(--teal)}.btn-ghost{background:transparent;border:1px solid var(--line)}.btn-danger{background:var(--red);color:#fff}.btn-wide{width:100%}.row{display:flex;gap:10px;align-items:center;flex-wrap:wrap}.fine{font-size:12px;color:var(--muted);line-height:1.45}.empty{text-align:center;padding:22px 10px;color:var(--muted)}.empty img{width:68px}.empty h3{color:var(--ink);margin-top:8px}.empty p{margin-bottom:0}
 .chat-page{display:flex;flex-direction:column;min-height:calc(100vh - 175px)}.chat-title{padding-bottom:8px}.agent-status{display:flex;align-items:center;gap:11px;padding:11px 13px;background:rgba(255,253,250,.7);border:1px solid var(--line);border-radius:17px;margin-bottom:12px}.agent-status>i{width:10px;height:10px;border-radius:50%;background:#a9a39d;box-shadow:0 0 0 5px rgba(169,163,157,.13)}.agent-status.connected>i{background:#209479;box-shadow:0 0 0 5px rgba(32,148,121,.13)}.agent-status.locked>i{background:#d19b27}.agent-status strong,.agent-status small{display:block}.agent-status strong{font-size:13px}.agent-status small{font-size:11px;color:var(--muted);margin-top:2px}.conversation{background:var(--surface);border:1px solid var(--line);border-radius:23px;padding:13px;box-shadow:0 10px 30px rgba(55,40,31,.05)}.chat{display:flex;flex-direction:column;gap:9px;min-height:195px;max-height:42vh;overflow:auto;padding:4px 1px 14px}.bubble{max-width:86%;padding:11px 13px;border-radius:17px;line-height:1.42;font-size:14px;white-space:pre-wrap}.bubble.timmy{align-self:flex-start;background:#efebe4;border-bottom-left-radius:5px}.bubble.user{align-self:flex-end;background:var(--teal);color:white;border-bottom-right-radius:5px}.thinking{display:flex;gap:4px}.thinking span{width:6px;height:6px;border-radius:50%;background:#8b847d;animation:blink 1s infinite}.thinking span:nth-child(2){animation-delay:.15s}.thinking span:nth-child(3){animation-delay:.3s}@keyframes blink{50%{opacity:.25;transform:translateY(-2px)}}.composer{display:grid;grid-template-columns:1fr 45px;gap:8px;align-items:end;background:#f0ece5;border-radius:18px;padding:6px}.composer textarea{border:0;background:transparent;resize:none;min-height:42px;max-height:110px;padding:10px 9px;outline:0;color:var(--ink)}.composer button{width:44px;height:44px;border:0;border-radius:14px;background:var(--ink);color:white;font-size:22px;cursor:pointer}.composer button:disabled{opacity:.4}.composer-note{font-size:10px;color:var(--muted);margin:7px 5px 0;line-height:1.35}.chat-error{font-size:12px;color:var(--red);margin:0 4px 8px}.safety-line{margin:13px 4px 0;color:var(--muted);font-size:11px;line-height:1.45}.safety-line strong{color:var(--ink)}.unlock-card{background:#fff8e6;border:1px solid #ead9a9;border-radius:20px;padding:14px;margin-bottom:12px}.unlock-card>label{display:block;font-size:12px;font-weight:800;margin-bottom:7px}.unlock-row{display:grid;grid-template-columns:1fr auto;gap:8px}.unlock-card .fine{margin:8px 2px 0}
-.sheet-backdrop{position:fixed;inset:0;background:rgba(28,22,18,.42);display:flex;align-items:flex-end;justify-content:center;z-index:50;padding-top:28px;backdrop-filter:blur(5px)}.sheet{width:min(100%,680px);max-height:94vh;overflow:auto;background:var(--surface);border-radius:28px 28px 0 0;padding:9px 18px calc(24px + env(safe-area-inset-bottom));box-shadow:0 -15px 50px rgba(30,22,18,.2)}.sheet-handle{width:38px;height:4px;background:#d8d1c8;border-radius:999px;margin:2px auto 15px}.sheet-header{display:flex;justify-content:space-between;align-items:flex-start;gap:12px}.sheet-header h2{margin-top:4px}.icon-btn{width:44px;height:44px;border:0;border-radius:50%;background:#efebe5;font-size:24px;cursor:pointer}.progress{height:4px;background:#eee8df;border-radius:99px;margin:7px 0 18px;overflow:hidden}.progress i{height:100%;display:block;background:var(--teal)}
+.sheet-backdrop{position:fixed;inset:0;background:rgba(28,22,18,.42);display:flex;align-items:flex-end;justify-content:center;z-index:50;padding-top:28px;backdrop-filter:blur(5px)}.sheet{width:min(100%,680px);max-height:94vh;overflow:auto;background:var(--surface);border-radius:28px 28px 0 0;padding:9px 18px calc(24px + env(safe-area-inset-bottom));box-shadow:0 -15px 50px rgba(30,22,18,.2)}.sheet-handle{width:38px;height:4px;background:#d8d1c8;border-radius:999px;margin:2px auto 15px}.sheet-header{display:flex;justify-content:space-between;align-items:flex-start;gap:12px}.sheet-header h2{margin-top:4px}.icon-btn{width:44px;height:44px;border:0;border-radius:50%;background:#efebe5;font-size:24px;cursor:pointer}.progress{height:4px;background:#eee8df;border-radius:99px;margin:7px 0 18px;overflow:hidden}.progress i{height:100%;display:block;background:var(--teal)}.progress-step-1{width:33.34%}.progress-step-2{width:66.68%}.progress-step-3{width:100%}
 .scan-hero{text-align:center;padding:3px 15px 12px}.scan-hero img{width:76px}.scan-hero h3{font-size:19px;margin:4px 0 7px}.scan-hero p{font-size:13px;line-height:1.45;color:var(--muted)}.model-status{border-radius:14px;padding:9px 11px;font-size:11px;font-weight:700;margin-bottom:12px}.model-status.ready{background:var(--teal-soft);color:var(--teal)}.model-status.offline{background:var(--red-soft);color:var(--red)}.model-status.checking{background:#f0ece5;color:var(--muted)}.photo-capture{display:grid;place-items:center;text-align:center;border:1.5px dashed #b9aea1;border-radius:21px;padding:22px;background:#faf7f1;cursor:pointer}.photo-capture b{font-size:30px}.photo-capture strong{margin:6px 0 2px}.photo-capture span{font-size:11px;color:var(--muted)}.photo-capture input{display:none}.photo-preview{display:block;width:100%;max-height:250px;object-fit:cover;border-radius:18px;margin:10px 0}.quality-note{font-size:12px;color:var(--muted)}.consent-card{background:#f5f1e9;border-radius:18px;padding:12px;margin:12px 0}.check{display:flex;gap:11px;align-items:flex-start;padding:9px 0}.check input{width:20px;height:20px;accent-color:var(--teal);flex:0 0 auto}.check span{font-size:13px;line-height:1.4}.analyzing{text-align:center;padding:33px 10px}.analyzing img{width:86px}.spinner{width:32px;height:32px;border:3px solid var(--soft);border-top-color:var(--teal);border-radius:50%;animation:spin .8s linear infinite;margin:10px auto}@keyframes spin{to{transform:rotate(360deg)}}.analyzing p{font-size:13px;color:var(--muted)}.scan-result{background:var(--teal-soft);border-radius:20px;padding:17px;margin-bottom:13px}.scan-result.needs-input{background:#f2eee7;text-align:center}.scan-result.needs-input>b{font-size:28px}.scan-result p{font-size:13px;line-height:1.45;margin:9px 0 0}.ai-badge{font-size:10px;font-weight:850;letter-spacing:.08em;color:var(--teal)}.suggestion-pair{display:grid;grid-template-columns:1fr 1fr;gap:9px;margin-top:12px}.suggestion-pair>div{background:var(--surface);padding:12px;border-radius:14px}.suggestion-pair small,.suggestion-pair strong{display:block}.suggestion-pair small{font-size:9px;color:var(--muted)}.suggestion-pair strong{font-size:18px;margin-top:2px}.ai-prefill{background:var(--teal-soft);border-radius:16px;padding:11px 13px;margin-bottom:12px}.ai-prefill strong,.ai-prefill small{display:block}.ai-prefill small{color:var(--muted);margin-top:3px}.choice-grid{display:grid;grid-template-columns:1fr 1fr;gap:8px}.bristol{min-height:66px;border:1px solid var(--line);background:#f7f3ed;border-radius:16px;padding:10px;text-align:left;cursor:pointer}.bristol strong,.bristol span{display:block}.bristol span{font-size:11px;color:var(--muted);margin-top:2px}.bristol.selected{background:var(--ink);color:white}.bristol.selected span{color:#ddd}.field{display:block;margin-bottom:15px}.field-label{display:block;font-size:12px;font-weight:800;margin-bottom:6px}.input{width:100%;min-height:48px;border:1px solid var(--line);border-radius:14px;background:#f8f5ef;padding:10px 12px;color:var(--ink)}textarea.input{min-height:85px;resize:vertical}.range-row{display:grid;grid-template-columns:1fr 37px;gap:10px;align-items:center}.range-row input{accent-color:var(--teal)}.range-val{width:37px;height:37px;border-radius:12px;background:var(--soft);display:grid;place-items:center;font-weight:800}.photo-drop{width:100%;background:#f3eee7}.symptoms{display:flex;flex-direction:column}.alert{background:var(--red-soft);border:1px solid #eec1ba;border-radius:16px;padding:13px;color:#75261f}.alert p{margin:5px 0 0;font-size:13px;line-height:1.4}
 .privacy-list{display:flex;flex-direction:column;gap:4px}.privacy-item{display:grid;grid-template-columns:40px 1fr;gap:11px;padding:11px 0;border-bottom:1px solid var(--line)}.privacy-item:last-child{border-bottom:0}.privacy-item>b{width:38px;height:38px;border-radius:13px;background:var(--teal-soft);display:grid;place-items:center;color:var(--teal)}.privacy-item h3{margin-bottom:4px}.privacy-item p,.source-list p{font-size:13px;line-height:1.45;color:var(--muted);margin-bottom:5px}.source-list a{color:var(--teal)}.danger-zone{border-color:#e9c4bf}.toast{position:fixed;left:50%;bottom:96px;transform:translateX(-50%);background:var(--ink);color:white;border-radius:999px;padding:11px 16px;font-size:13px;font-weight:700;z-index:100;box-shadow:var(--shadow)}
 .staging-label{margin:8px auto 86px;text-align:center;color:var(--muted);font-size:10px;letter-spacing:.03em;opacity:.72}

tests/agent-queue.test.js

@@ -0,0 +1,92 @@
+import test from 'node:test';
+import assert from 'node:assert/strict';
+
+import { AgentGatewayError, createHermesAgentService, resolveHermesAgentConfig } from '../src/hermes-agent-service.js';
+
+const origin = 'http://127.0.0.1:4173';
+const accessCode = 'test-agent-access-code-2026';
+const configured = () => resolveHermesAgentConfig({
+  TIMMY_AGENT_ENABLED: 'true',
+  TIMMY_AGENT_ACCESS_TOKEN: accessCode,
+  TIMMY_PUBLIC_ORIGIN: origin,
+  TIMMY_AGENT_WORKDIR: '/tmp/timmy-agent-workspace',
+});
+
+function deferred() {
+  let resolve;
+  let reject;
+  const promise = new Promise((res, rej) => { resolve = res; reject = rej; });
+  return { promise, resolve, reject };
+}
+
+async function unlock(service, token) {
+  await service.unlock({ origin, accessCode });
+  return token;
+}
+
+test('chat requests beyond the queue depth get a stable sanitized overload fallback', async () => {
+  let clock = 0;
+  const gate = deferred();
+  let started = 0;
+  const service = createHermesAgentService({
+    config: { ...configured(), maxQueueDepth: 1 },
+    randomToken: () => 'queue-cookie',
+    now: () => clock,
+    runTurn: async () => {
+      started += 1;
+      return gate.promise;
+    },
+  });
+  await unlock(service);
+
+  const first = service.chat({ origin, cookieToken: 'queue-cookie', payload: { message: 'first', ledger: [] } });
+  await new Promise(resolve => setImmediate(resolve));
+  assert.equal(started, 1);
+
+  const second = service.chat({ origin, cookieToken: 'queue-cookie', payload: { message: 'second', ledger: [] } });
+  await new Promise(resolve => setImmediate(resolve));
+  assert.equal(started, 1, 'second request waits in the bounded queue');
+
+  await assert.rejects(() => service.chat({ origin, cookieToken: 'queue-cookie', payload: { message: 'third', ledger: [] } }), error => {
+    assert.equal(error.status, 503);
+    assert.match(error.message, /busy|try again/i);
+    assert.doesNotMatch(error.message, /spawn|hermes|session|token|workdir/i);
+    return true;
+  }, 'request beyond max queue depth fails fast with sanitized copy');
+
+  gate.resolve({ reply: 'eventually', sessionId: 'private-session' });
+  assert.match((await first).reply, /eventually/);
+  assert.match((await second).reply, /eventually/);
+});
+
+test('a chat request abandoned by its browser is cancelled without running Hermes and frees its slot', async () => {
+  let clock = 0;
+  const gate = deferred();
+  const started = [];
+  const service = createHermesAgentService({
+    config: { ...configured(), maxQueueDepth: 2 },
+    randomToken: () => 'disconnect-cookie',
+    now: () => clock,
+    runTurn: async ({ signal }) => {
+      started.push('run');
+      return new Promise((resolve, reject) => {
+        signal.addEventListener('abort', () => reject(new Error('aborted')));
+        gate.promise.then(resolve, reject);
+      });
+    },
+  });
+  await unlock(service, 'disconnect-cookie');
+
+  const active = service.chat({ origin, cookieToken: 'disconnect-cookie', payload: { message: 'holding slot', ledger: [] } });
+  await new Promise(resolve => setImmediate(resolve));
+  const abandonSignal = new AbortController();
+  const abandoned = service.chat({ origin, cookieToken: 'disconnect-cookie', payload: { message: 'queued', ledger: [] }, signal: abandonSignal.signal });
+  await new Promise(resolve => setImmediate(resolve));
+
+  abandonSignal.abort(new Error('client disconnected'));
+  await assert.rejects(() => abandoned, error => error.status === 503 && /closed|disconnect/i.test(error.message));
+
+  gate.resolve({ reply: 'late answer', sessionId: 'private-session' });
+  assert.match((await active).reply, /late answer/);
+  assert.deepEqual(started, ['run'], 'the cancelled request never invoked a Hermes turn');
+});

tests/agent-turn-timeout.test.js

@@ -0,0 +1,109 @@
+import test from 'node:test';
+import assert from 'node:assert/strict';
+
+import { chmod, mkdir, rm, writeFile } from 'node:fs/promises';
+import { tmpdir } from 'node:os';
+import { join } from 'node:path';
+import { constants as fsConstants } from 'node:fs';
+
+import { AgentGatewayError, createHermesAgentService, resolveHermesAgentConfig, runHermesCliTurn } from '../src/hermes-agent-service.js';
+
+const origin = 'http://127.0.0.1:4173';
+const accessCode = 'test-agent-access-code-2026';
+const configured = () => resolveHermesAgentConfig({
+  TIMMY_AGENT_ENABLED: 'true',
+  TIMMY_AGENT_ACCESS_TOKEN: accessCode,
+  TIMMY_PUBLIC_ORIGIN: origin,
+  TIMMY_AGENT_WORKDIR: '/tmp/timmy-agent-workspace',
+});
+
+async function waitUntil(check, timeoutMs = 3_000, stepMs = 20) {
+  const deadline = Date.now() + timeoutMs;
+  while (Date.now() < deadline) {
+    if (await check()) return true;
+    await new Promise(resolve => setTimeout(resolve, stepMs));
+  }
+  return false;
+}
+
+function isAlive(pid) {
+  try { process.kill(pid, 0); return true; } catch (error) { return error.code === 'EPERM'; }
+}
+
+test('aborting an in-flight Hermes turn kills the child promptly and leaves no orphan process', async () => {
+  const dir = await mkdir(join(tmpdir(), `timmy-orphan-${Date.now()}-`), { recursive: true });
+  const pidFile = join(dir, 'child.pid');
+  const fixture = join(dir, 'slow-hermes.sh');
+  // Prints valid Hermes output immediately, then idles long enough that only
+  // an explicit kill can end it. `exec` makes the recorded PID the sleeper.
+  await writeFile(fixture, `#!/usr/bin/env bash\nprintf '%s\\n' $$ > '${pidFile}'\necho "session_id: fixture_kill_001"\necho "thinking"\nexec sleep 60\n`, { mode: fsConstants.S_IRWXU });
+
+  const controller = new AbortController();
+  const turn = runHermesCliTurn({
+    prompt: 'hello',
+    hermesSessionId: null,
+    config: { ...configured(), command: fixture, workdir: dir },
+    signal: controller.signal,
+    env: { TMPDIR: dir },
+  });
+
+  const pidAppeared = await waitUntil(async () => {
+    try { Number(await (await import('node:fs/promises')).readFile(pidFile, 'utf8')); return true; } catch { return false; }
+  }, 4_000);
+  assert.ok(pidAppeared, 'fixture child started');
+  const pid = Number(await (await import('node:fs/promises')).readFile(pidFile, 'utf8'));
+  assert.ok(isAlive(pid), 'child is running before cancellation');
+
+  const startedAt = Date.now();
+  controller.abort(new Error('client disconnected'));
+  await assert.rejects(() => Promise.race([
+    turn,
+    new Promise((_, reject) => setTimeout(() => reject(new Error('turn was not cancelled')), 5_000)),
+  ]), error => /disconnect|abort|killed|terminated/i.test(String(error?.message || error?.code || '')));
+  const cancelMs = Date.now() - startedAt;
+  assert.ok(cancelMs < 4_000, `cancellation returned promptly (took ${cancelMs}ms)`);
+
+  const reaped = await waitUntil(() => !isAlive(pid), 4_000);
+  assert.ok(reaped, 'child process was actually killed — no orphan subprocess remains');
+  await rm(dir, { recursive: true, force: true });
+}, { timeout: 20_000 });
+
+test('a queued chat past the queue deadline is cleaned up with a sanitized timeout response and zero extra Hermes calls', async () => {
+  let clock = 0;
+  let started = 0;
+  let releaseActive;
+  const service = createHermesAgentService({
+    config: { ...configured(), timeoutMs: 50 },
+    randomToken: () => 'deadline-cookie',
+    now: () => clock,
+    runTurn: async () => {
+      started += 1;
+      return new Promise(resolve => { releaseActive = resolve; });
+    },
+  });
+  await service.unlock({ origin, accessCode });
+
+  const active = service.chat({ origin, cookieToken: 'deadline-cookie', payload: { message: 'wedge', ledger: [] } });
+  await new Promise(resolve => setImmediate(resolve));
+  assert.equal(started, 1);
+
+  const queued = service.chat({ origin, cookieToken: 'deadline-cookie', payload: { message: 'waiting', ledger: [] } });
+  await new Promise(resolve => setImmediate(resolve));
+  assert.equal(started, 1);
+
+  clock += 200; // past the 50ms queue deadline
+  // Attach the rejection expectation before the sweep runs so the expired
+  // request never counts as an unhandled rejection.
+  const expiryExpectation = assert.rejects(() => queued, error => {
+    assert.ok(error instanceof AgentGatewayError);
+    assert.equal(error.status, 503);
+    assert.match(error.message, /timed out|busy/i);
+    assert.doesNotMatch(error.message, /spawn|hermes|session|token|workdir|auth/i);
+    return true;
+  });
+  service.chat({ origin, cookieToken: 'deadline-cookie', payload: { message: 'sweep trigger', ledger: [] } }).catch(() => {});
+  await expiryExpectation;
+  assert.equal(started, 1, 'expired request never reached Hermes');
+  releaseActive({ reply: 'late but valid', sessionId: 'deadline_session_01' });
+  assert.match((await active).reply, /late but valid/);
+});

tests/fixtures/slow-hermes.mjs

@@ -0,0 +1,20 @@
+#!/usr/bin/env node
+// Slow Hermes fixture for bounded-queue acceptance tests. Normal prompts
+// answer immediately; prompts containing HOLD block until a release file
+// appears inside the agent workdir (the value after `--in`), so tests can
+// saturate the queue deterministically without touching shared /tmp state.
+import { existsSync } from 'node:fs';
+import { appendFileSync } from 'node:fs';
+
+const args = process.argv.slice(2);
+const promptIndex = args.indexOf('-q');
+const prompt = promptIndex >= 0 ? args[promptIndex + 1] : '';
+const workdirIndex = args.indexOf('--in');
+const workdir = workdirIndex >= 0 ? args[workdirIndex + 1] : '/tmp';
+appendFileSync(`${workdir}/fixture-pids.log`, `${process.pid}\n`);
+process.stdout.write('session_id: slow_fixture_2026\n');
+if (/HOLD/.test(prompt)) {
+  const releaseFile = `${workdir}/hermes-release`;
+  while (!existsSync(releaseFile)) await new Promise(resolve => setTimeout(resolve, 20));
+}
+process.stdout.write('Hermes fixture answered the bounded request.\n');

tests/hermes-agent-service.test.js

@@ -193,16 +193,21 @@ test('Hermes child receives only an explicit non-secret environment allowlist',
   });
 });
 
-test('upstream failures and concurrency fail closed without leaking process detail', async () => {
+test('saturated turns queue within bounds and excess load fails closed without leaking process detail', async () => {
   let release;
   const runTurn = () => new Promise(resolve => { release = resolve; });
-  const service = createHermesAgentService({ config: configured(), randomToken: () => 'browser-cookie', runTurn });
+  const service = createHermesAgentService({ config: { ...configured(), maxQueueDepth: 1 }, randomToken: () => 'browser-cookie', runTurn });
   await service.unlock({ origin, accessCode: 'test-agent-access-code-2026' });
   const active = service.chat({ origin, cookieToken: 'browser-cookie', payload: { message: 'first', ledger: [] } });
   await new Promise(resolve => setImmediate(resolve));
-  await rejectsStatus(() => service.chat({ origin, cookieToken: 'browser-cookie', payload: { message: 'second', ledger: [] } }), 429);
-  release({ reply: 'done', sessionId: 'private-session' });
-  await active;
+  const queued = service.chat({ origin, cookieToken: 'browser-cookie', payload: { message: 'second', ledger: [] } });
+  await new Promise(resolve => setImmediate(resolve));
+  await rejectsStatus(() => service.chat({ origin, cookieToken: 'browser-cookie', payload: { message: 'third', ledger: [] } }), 503);
+  release({ reply: 'first done', sessionId: 'private-session' });
+  assert.match((await active).reply, /first done/);
+  await new Promise(resolve => setImmediate(resolve));
+  release({ reply: 'queued done', sessionId: 'private-session' });
+  assert.match((await queued).reply, /queued done/);
 
   const broken = createHermesAgentService({ config: configured(), randomToken: () => 'broken-cookie', runTurn: async () => { throw new Error('spawn /root/.hermes/auth.json SECRET'); } });
   await broken.unlock({ origin, accessCode: 'test-agent-access-code-2026' });

tests/inference-queue-cancellation.test.js

@@ -0,0 +1,96 @@
+import test from 'node:test';
+import assert from 'node:assert/strict';
+
+import { OverloadError, createInferenceQueue } from '../src/inference-queue.js';
+
+function deferred() {
+  let resolve;
+  let reject;
+  const promise = new Promise((res, rej) => { resolve = res; reject = rej; });
+  return { promise, resolve, reject };
+}
+
+test('a queued request past its deadline is expired deterministically and its place is reusable', async () => {
+  let clock = 0;
+  const queue = createInferenceQueue({ concurrency: 1, maxQueueDepth: 1, requestTimeoutMs: 100, now: () => clock });
+
+  const wedgeGate = deferred();
+  const active = queue.run(signal => {
+    return new Promise((resolve, reject) => {
+      signal.addEventListener('abort', () => reject(new Error('upstream aborted')));
+      wedgeGate.promise.then(resolve, reject);
+    });
+  });
+  active.catch(() => {});
+  await Promise.resolve();
+
+  let started = false;
+  const queued = queue.run(() => { started = true; return 'never'; });
+  await Promise.resolve();
+
+  clock += 150; // deadline (submitted at t=0, limit 100) has elapsed
+  const probe = queue.run(() => 'ok'); // queue activity triggers the deadline sweep
+
+  await assert.rejects(() => queued, error => {
+    assert.ok(error instanceof OverloadError);
+    assert.match(error.message, /timed out|busy/i);
+    return true;
+  });
+  assert.equal(started, false, 'the expired request must never reach the provider');
+
+  // Capacity is intact: cancelling the wedged holder lets the surviving request through.
+  queue.cancel(active, 'cleanup');
+  assert.equal(await Promise.race([probe, new Promise((_, reject) => setTimeout(() => reject(new Error('probe starved')), 200))]), 'ok');
+});
+
+test('client disconnect cancels a queued request before it reaches the provider', async () => {
+  let clock = 0;
+  const queue = createInferenceQueue({ concurrency: 1, maxQueueDepth: 2, requestTimeoutMs: 60_000, now: () => clock });
+
+  const wedgeGate = deferred();
+  const active = queue.run(() => wedgeGate.promise);
+  active.catch(() => {});
+  await Promise.resolve();
+
+  let sawStart = false;
+  const queued = queue.run(() => { sawStart = true; return 'too late'; });
+  await Promise.resolve();
+
+  queue.cancel(queued, 'client disconnected');
+  await assert.rejects(() => queued, error => error.message === 'client disconnected');
+  assert.equal(sawStart, false, 'cancelled request never invoked its task');
+
+  const admitted = queue.run(() => 'admitted-after-cancel');
+  wedgeGate.resolve('wedge-done');
+  assert.equal(await admitted, 'admitted-after-cancel');
+  assert.equal(await active, 'wedge-done');
+});
+
+test('cancelling an already-running task aborts its signal so buffers can be released', async () => {
+  let clock = 0;
+  const queue = createInferenceQueue({ concurrency: 1, maxQueueDepth: 1, requestTimeoutMs: 60_000, now: () => clock });
+
+  const observed = [];
+  const running = queue.run(async signal => {
+    observed.push(signal);
+    signal.addEventListener('abort', () => observed.push(`aborted:${signal.reason?.message ?? signal.reason}`));
+    await new Promise((resolve, reject) => {
+      signal.addEventListener('abort', () => reject(new Error('task stopped')));
+      setTimeout(resolve, 5_000);
+    });
+  });
+
+  // Let the wrapper admit the request and actually invoke the task body.
+  await Promise.resolve();
+  await Promise.resolve();
+  assert.equal(observed.length, 1, 'task is genuinely running before cancellation');
+
+  queue.cancel(running, 'stop');
+  await assert.rejects(() => running, /task stopped/);
+  assert.ok(observed[0] instanceof AbortSignal, 'task received a real AbortSignal');
+  assert.match(String(observed[1]), /stop/, 'running task observed the abort with its reason');
+
+  // The slot was released by the cancelled task, so the next request starts immediately.
+  const next = queue.run(() => 'next-runs');
+  assert.equal(await next, 'next-runs');
+});

tests/inference-queue.acceptance.mjs

@@ -0,0 +1,136 @@
+import test from 'node:test';
+import assert from 'node:assert/strict';
+import { chmod, mkdtemp, rm, readFile, writeFile } from 'node:fs/promises';
+import { spawn } from 'node:child_process';
+import { tmpdir } from 'node:os';
+import { join } from 'node:path';
+import { constants as fsConstants } from 'node:fs';
+import { fileURLToPath } from 'node:url';
+
+const root = fileURLToPath(new URL('..', import.meta.url));
+const fixture = fileURLToPath(new URL('./fixtures/slow-hermes.mjs', import.meta.url));
+const origin = 'http://127.0.0.1:4187';
+const accessCode = 'queue-acceptance-code-2026';
+
+async function waitReady(child) {
+  const deadline = Date.now() + 10_000;
+  while (Date.now() < deadline) {
+    if (child.exitCode !== null) throw new Error(`server exited ${child.exitCode}`);
+    try { const response = await fetch(`${origin}/api/healthz`); if (response.ok) return; } catch {}
+    await new Promise(resolve => setTimeout(resolve, 50));
+  }
+  throw new Error('server did not become ready');
+}
+
+function post(path, body, { cookie = '', signal } = {}) {
+  return fetch(`${origin}${path}`, {
+    method: 'POST',
+    headers: {
+      'content-type': 'application/json',
+      origin,
+      'sec-fetch-site': 'same-origin',
+      ...(cookie ? { cookie } : {}),
+    },
+    body: JSON.stringify(body),
+    signal,
+  }).then(
+    async response => ({ status: response.status, body: await response.json().catch(() => ({})) }),
+    error => ({ failed: true, reason: String(error?.name || error) }),
+  );
+}
+
+test('bounded queue end-to-end: disconnect cleanup, overload fallback, urgent bypass, recovery', async t => {
+  const workdir = await mkdtemp(join(tmpdir(), 'timmy-queue-accept-'));
+  const releaseFile = join(workdir, 'hermes-release');
+  const pidLog = join(workdir, 'fixture-pids.log');
+  await chmod(fixture, fsConstants.S_IRWXU);
+  const child = spawn(process.execPath, ['server.mjs'], {
+    cwd: root,
+    env: {
+      ...process.env,
+      PORT: '4187',
+      TIMMY_AGENT_ENABLED: 'true',
+      TIMMY_AGENT_ACCESS_TOKEN: accessCode,
+      TIMMY_PUBLIC_ORIGIN: origin,
+      TIMMY_AGENT_WORKDIR: workdir,
+      TIMMY_HERMES_COMMAND: fixture,
+      TIMMY_AGENT_MAX_CONCURRENT_TURNS: '1',
+      TIMMY_AGENT_MAX_QUEUE_DEPTH: '2',
+    },
+    stdio: ['ignore', 'pipe', 'pipe'],
+  });
+  let serverLogs = '';
+  child.stderr.on('data', chunk => { serverLogs += String(chunk); });
+  t.after(async () => {
+    child.kill('SIGTERM');
+    await rm(workdir, { recursive: true, force: true }).catch(() => {});
+    await rm(releaseFile, { force: true }).catch(() => {});
+  });
+  await waitReady(child);
+
+  // Authenticate once and keep the cookie for the whole scenario.
+  const rawResponse = await fetch(`${origin}/api/agent/unlock`, {
+    method: 'POST',
+    headers: { 'content-type': 'application/json', origin, 'sec-fetch-site': 'same-origin' },
+    body: JSON.stringify({ accessCode }),
+  });
+  assert.equal(rawResponse.status, 200);
+  const browserCookie = rawResponse.headers.get('set-cookie').split(';', 1)[0];
+
+  // Fill the slot: this HOLD runs until the fixture release file appears.
+  const heldOne = post('/api/agent/chat', { message: 'HOLD one', ledger: [] }, { cookie: browserCookie });
+  await new Promise(resolve => setTimeout(resolve, 400));
+
+  // 1. Disconnect cleanup: this request waits in the queue. When its client
+  //    vanishes, Timmy must drop it and free the queued place.
+  const disconnectController = new AbortController();
+  const doomed = post('/api/agent/chat', { message: 'HOLD doomed', ledger: [] }, { cookie: browserCookie, signal: disconnectController.signal });
+  await new Promise(resolve => setTimeout(resolve, 400));
+  disconnectController.abort();
+  const doomedOutcome = await doomed;
+  assert.equal(doomedOutcome.failed, true, 'abandoned client saw its request cancelled');
+
+  // If the freed place was reclaimed, both follow-up HOLDs are admitted
+  // (slot + queue of two minus one freed place). A sanitized 503 here would
+  // mean the cancelled client did not release capacity.
+  const heldTwo = post('/api/agent/chat', { message: 'HOLD two', ledger: [] }, { cookie: browserCookie });
+  const heldThree = post('/api/agent/chat', { message: 'HOLD three', ledger: [] }, { cookie: browserCookie });
+  await new Promise(resolve => setTimeout(resolve, 500));
+
+  // 2. Overload: everything is saturated now, so a further request must fail
+  //    fast with the stable manual-fallback copy and zero provider contact.
+  const overloadResult = await post('/api/agent/chat', { message: 'overload probe', ledger: [] }, { cookie: browserCookie });
+  assert.equal(overloadResult.status, 503);
+  assert.match(overloadResult.body.error, /busy|try again|manually/i);
+  assert.doesNotMatch(overloadResult.body.error, /spawn|hermes|session|token|workdir|fixture/i);
+
+  // 3. Urgent bypass while saturated: deterministic safety answer, zero calls.
+  const urgentResult = await post('/api/agent/chat', { message: 'I have rectal bleeding', ledger: [] }, { cookie: browserCookie });
+  assert.equal(urgentResult.status, 200);
+  assert.equal(urgentResult.body.safetyOverride, true);
+  assert.match(urgentResult.body.reply, /medical help/i);
+
+  // 4. Recovery: releasing the fixture lets every surviving request complete.
+  await writeFile(releaseFile, 'go');
+  for (const [label, promise] of [['one', heldOne], ['two', heldTwo], ['three', heldThree]]) {
+    const settled = await Promise.race([
+      promise,
+      new Promise(resolve => setTimeout(() => resolve({ status: 'TEST-TIMEOUT' }), 12_000)),
+    ]);
+    assert.equal(settled.status, 200, `${label} completed after recovery`);
+    assert.match(settled.body.reply, /bounded request/);
+    assert.doesNotMatch(JSON.stringify(settled.body), /slow_fixture_2026|session_id/);
+  }
+
+  // 5. No orphan subprocesses: every fixture PID recorded at spawn is gone.
+  await new Promise(resolve => setTimeout(resolve, 400));
+  const recordedPids = ((await readFile(pidLog, 'utf8').catch(() => '')) || '')
+    .split('\n').map(Number).filter(Boolean);
+  assert.equal(recordedPids.length, 3, `exactly three turns ran (saw ${recordedPids.length})`);
+  for (const pid of [...new Set(recordedPids)]) {
+    let alive = true;
+    try { process.kill(pid, 0); } catch { alive = false; }
+    assert.equal(alive, false, `fixture process ${pid} outlived its turn`);
+  }
+  assert.doesNotMatch(serverLogs, /access-code|secret|token/i);
+}, { timeout: 40_000 });

tests/inference-queue.test.js

@@ -0,0 +1,72 @@
+import test from 'node:test';
+import assert from 'node:assert/strict';
+
+import { OverloadError, createInferenceQueue } from '../src/inference-queue.js';
+
+function deferred() {
+  let resolve;
+  let reject;
+  const promise = new Promise((res, rej) => { resolve = res; reject = rej; });
+  return { promise, resolve, reject };
+}
+
+test('vision analysis runs with bounded concurrency and strict FIFO ordering', async () => {
+  let clock = 0;
+  const gates = new Map();
+  const started = [];
+  const queue = createInferenceQueue({ concurrency: 2, maxQueueDepth: 4, requestTimeoutMs: 10_000, now: () => clock });
+
+  const run = label => queue.run(signal => {
+    started.push(label);
+    const gate = deferred();
+    gates.set(label, gate);
+    gate.promise.catch(() => {});
+    return gate.promise;
+  });
+
+  const first = run('first');
+  const second = run('second');
+  const third = run('third');
+  const fourth = run('fourth');
+  while (started.length < 2) await Promise.resolve();
+  assert.deepEqual(started, ['first', 'second'], 'only concurrency slots start immediately');
+
+  gates.get('first').resolve({ ok: 'first' });
+  assert.equal((await first).ok, 'first');
+
+  // The slot freed by `first` must be granted to `third` (head of the queue).
+  while (!gates.has('third')) await Promise.resolve();
+  gates.get('third').resolve({ ok: 'third' });
+
+  // Only after `third` releases its slot may `fourth` start.
+  while (!gates.has('fourth')) await Promise.resolve();
+  gates.get('second').resolve({ ok: 'second' });
+  gates.get('fourth').resolve({ ok: 'fourth' });
+
+  assert.deepEqual(await Promise.all([second, third, fourth]), [{ ok: 'second' }, { ok: 'third' }, { ok: 'fourth' }]);
+  assert.equal(started.length, 4, 'every admitted request eventually started');
+  assert.deepEqual([...new Set(started)], ['first', 'second', 'third', 'fourth'], 'each queued request started exactly once');
+  assert.equal(started.indexOf('third') < started.indexOf('fourth'), true, 'queued requests were granted in FIFO order');
+});
+
+test('overloaded submissions fail fast with a stable sanitized manual-fallback error', async () => {
+  let clock = 0;
+  const gates = [];
+  const queue = createInferenceQueue({ concurrency: 1, maxQueueDepth: 1, requestTimeoutMs: 10_000, now: () => clock });
+
+  const hold = queue.run(() => { const gate = deferred(); gates.push(gate); gate.promise.catch(() => {}); return gate.promise; });
+  await Promise.resolve();
+  const held = queue.run(() => new Promise(() => {}));
+  await Promise.resolve();
+
+  await assert.rejects(() => queue.run(() => new Promise(() => {})), error => {
+    assert.ok(error instanceof OverloadError);
+    assert.match(error.message, /busy|full/i);
+    assert.doesNotMatch(error.message, /stack|internal|fetch|127\.0\.0\.1/i);
+    return true;
+  }, 'excess request beyond maxQueueDepth is rejected immediately');
+
+  // Active and already-queued work continues unaffected by the rejected submission.
+  gates[0].resolve('done');
+  assert.equal(await hold, 'done');
+});

tests/inference-zero-call.test.js

@@ -0,0 +1,108 @@
+import test from 'node:test';
+import assert from 'node:assert/strict';
+
+import { createHermesAgentService, resolveHermesAgentConfig } from '../src/hermes-agent-service.js';
+import { analyzePhoto } from '../src/vision-service.js';
+import { OverloadError, createInferenceQueue } from '../src/inference-queue.js';
+
+const origin = 'http://127.0.0.1:4173';
+const accessCode = 'test-agent-access-code-2026';
+const configured = () => resolveHermesAgentConfig({
+  TIMMY_AGENT_ENABLED: 'true',
+  TIMMY_AGENT_ACCESS_TOKEN: accessCode,
+  TIMMY_PUBLIC_ORIGIN: origin,
+  TIMMY_AGENT_WORKDIR: '/tmp/timmy-agent-workspace',
+});
+
+function deferred() {
+  let resolve;
+  let reject;
+  const promise = new Promise((res, rej) => { resolve = res; reject = rej; });
+  return { promise, resolve, reject };
+}
+
+test('urgent messages intercept before Hermes even when the queue is saturated', async () => {
+  let clock = 0;
+  let hermesCalls = 0;
+  const gate = deferred();
+  const service = createHermesAgentService({
+    config: { ...configured(), maxQueueDepth: 0 },
+    randomToken: () => 'urgent-cookie',
+    now: () => clock,
+    runTurn: async () => {
+      hermesCalls += 1;
+      return gate.promise;
+    },
+  });
+  await service.unlock({ origin, accessCode });
+
+  // Saturate the single slot so any queued path would be rejected as overloaded.
+  const active = service.chat({ origin, cookieToken: 'urgent-cookie', payload: { message: 'normal question', ledger: [] } });
+  await new Promise(resolve => setImmediate(resolve));
+  assert.equal(hermesCalls, 1);
+
+  const urgent = await service.chat({ origin, cookieToken: 'urgent-cookie', payload: { message: 'I have rectal bleeding', ledger: [] } });
+
+  assert.equal(hermesCalls, 1, 'Hermes was called exactly once — only for the non-urgent request');
+  assert.equal(urgent.safetyOverride, true);
+  assert.match(urgent.reply, /medical help/i);
+  gate.resolve({ reply: 'late', sessionId: 'urgent_session_01' });
+  assert.match((await active).reply, /late/);
+});
+
+test('vision analysis is bounded by the shared queue and overload returns the manual-fallback copy', async () => {
+  let clock = 0;
+  let providerCalls = 0;
+  const gates = [];
+  const queue = createInferenceQueue({ concurrency: 1, maxQueueDepth: 1, requestTimeoutMs: 60_000, now: () => clock });
+
+  const visionFetch = async (url, options) => {
+    providerCalls += 1;
+    const gate = deferred();
+    gates.push(gate);
+    options.signal?.addEventListener('abort', () => gate.reject(new Error('aborted')));
+    return new Promise((resolve, reject) => {
+      gate.promise.then(() => resolve({ ok: true, json: async () => ({ choices: [{ message: { content: JSON.stringify({ isStool: true, bristolType: 4, color: 'brown', confidence: 0.8, imageQuality: 'good', observations: 'ok' }) } }] }) }), reject);
+    });
+  };
+
+  const payload = { imageDataUrl: 'data:image/jpeg;base64,YQ==', consent: true };
+  const config = { baseUrl: 'http://127.0.0.1:8645/v1', apiKey: 'test-key-not-real', model: 'm' };
+
+  const first = queue.run(signal => analyzePhoto({ payload, fetchImpl: visionFetch, config, signal }));
+  while (providerCalls < 1) await Promise.resolve();
+  const second = queue.run(signal => analyzePhoto({ payload, fetchImpl: visionFetch, config, signal }));
+  await Promise.resolve();
+
+  await assert.rejects(() => queue.run((signal) => analyzePhoto({ payload, fetchImpl: visionFetch, config, signal })), error => {
+    assert.ok(error instanceof OverloadError);
+    assert.match(error.message, /continue manually/i);
+    assert.doesNotMatch(error.message, /api|key|token|127\.0\.0\.1|fetch/i);
+    return true;
+  }, 'third request beyond depth is overloaded with sanitized copy');
+
+  assert.equal(providerCalls, 1, 'overloaded request never reached the provider');
+  gates[0].resolve('go');
+  const result = await Promise.race([first, new Promise(resolve => setTimeout(() => resolve('pending'), 100))]);
+  assert.notEqual(result, 'pending');
+});
+
+test('vision requests carry cancellation so disconnected clients release provider work', async () => {
+  let capturedSignal;
+  const controller = new AbortController();
+  const gate = deferred();
+  const fetchImpl = async (url, options) => {
+    capturedSignal = options.signal;
+    options.signal?.addEventListener('abort', () => gate.reject(new Error('aborted')));
+    return gate.promise;
+  };
+  const payload = { imageDataUrl: 'data:image/jpeg;base64,YQ==', consent: true };
+  const config = { baseUrl: 'http://127.0.0.1:8645/v1', apiKey: 'test-key-not-real', model: 'm' };
+
+  const attempt = analyzePhoto({ payload, fetchImpl, config, signal: controller.signal });
+  while (!capturedSignal) await Promise.resolve();
+
+  controller.abort(new Error('client disconnected'));
+  await assert.rejects(() => attempt, /continue manually|unavailable/i);
+  assert.equal(capturedSignal.aborted, true, 'the provider fetch observed the cancellation');
+});

tests/server-shutdown.acceptance.mjs

@@ -0,0 +1,93 @@
+import test from 'node:test';
+import assert from 'node:assert/strict';
+import { chmod, mkdtemp, rm, readFile } from 'node:fs/promises';
+import { spawn } from 'node:child_process';
+import { tmpdir } from 'node:os';
+import { join } from 'node:path';
+import { constants as fsConstants } from 'node:fs';
+import { fileURLToPath } from 'node:url';
+
+const root = fileURLToPath(new URL('..', import.meta.url));
+const fixture = fileURLToPath(new URL('./fixtures/slow-hermes.mjs', import.meta.url));
+
+test('server shutdown cancels in-flight turns and leaves no orphan Hermes subprocesses', async () => {
+  const workdir = await mkdtemp(join(tmpdir(), 'timmy-shutdown-'));
+  await chmod(fixture, fsConstants.S_IRWXU);
+  const child = spawn(process.execPath, ['server.mjs'], {
+    cwd: root,
+    env: {
+      ...process.env,
+      HOST: '127.0.0.1',
+      PORT: '4188',
+      TIMMY_AGENT_ENABLED: 'true',
+      TIMMY_AGENT_ACCESS_TOKEN: 'shutdown-accept-code-2026',
+      TIMMY_PUBLIC_ORIGIN: 'http://127.0.0.1:4188',
+      TIMMY_AGENT_WORKDIR: workdir,
+      TIMMY_HERMES_COMMAND: fixture,
+    },
+    stdio: ['ignore', 'pipe', 'pipe'],
+  });
+  let reportedOrigin = '';
+  child.stdout.on('data', chunk => {
+    const match = String(chunk).match(/listening on http:\/\/([^:]+):(\d+)/);
+    if (match && !reportedOrigin) reportedOrigin = `http://${match[1]}:${match[2]}`;
+  });
+  const deadline = Date.now() + 10_000;
+  while (!reportedOrigin && Date.now() < deadline && child.exitCode === null) {
+    await new Promise(resolve => setTimeout(resolve, 50));
+  }
+  assert.ok(reportedOrigin, 'server reported its port');
+
+  const unlockResponse = await fetch(`${reportedOrigin}/api/agent/unlock`, {
+    method: 'POST',
+    headers: { 'content-type': 'application/json', origin: reportedOrigin, 'sec-fetch-site': 'same-origin' },
+    body: JSON.stringify({ accessCode: 'shutdown-accept-code-2026' }),
+  });
+  assert.equal(unlockResponse.status, 200);
+  const browserCookie = unlockResponse.headers.get('set-cookie').split(';', 1)[0];
+
+  // Start a turn wedged on the fixture's HOLD gate.
+  fetch(`${reportedOrigin}/api/agent/chat`, {
+    method: 'POST',
+    headers: { 'content-type': 'application/json', origin: reportedOrigin, 'sec-fetch-site': 'same-origin', cookie: browserCookie },
+    body: JSON.stringify({ message: 'HOLD shutdown probe', ledger: [] }),
+  }).catch(() => {});
+  await new Promise(resolve => setTimeout(resolve, 600));
+
+  const pidLog = join(workdir, 'fixture-pids.log');
+  // Wait until the fixture for this run's HOLD turn is actually alive.
+  let lastPid = null;
+  const spawnDeadline = Date.now() + 8_000;
+  while (Date.now() < spawnDeadline) {
+    const recorded = ((await readFile(pidLog, 'utf8').catch(() => '')) || '')
+      .split('\n').map(Number).filter(Boolean);
+    const candidate = recorded.at(-1);
+    if (candidate) {
+      let alive = true;
+      try { process.kill(candidate, 0); } catch { alive = false; }
+      if (alive) {
+        lastPid = candidate;
+        break;
+      }
+    }
+    await new Promise(resolve => setTimeout(resolve, 100));
+  }
+  assert.ok(lastPid, 'fixture subprocess was spawned for the in-flight turn');
+  let aliveBefore = true;
+  try { process.kill(lastPid, 0); } catch { aliveBefore = false; }
+  assert.ok(aliveBefore, `fixture ${lastPid} is running before shutdown`);
+
+  // Shut the server down while the turn is still running.
+  child.kill('SIGTERM');
+  await new Promise((resolve, reject) => {
+    const timeout = setTimeout(() => reject(new Error('server did not exit after SIGTERM')), 5_000);
+    child.on('exit', code => { clearTimeout(timeout); resolve(code); });
+  });
+
+  // The in-flight fixture must be gone — no orphan subprocess may survive.
+  await new Promise(resolve => setTimeout(resolve, 500));
+  let aliveAfter = true;
+  try { process.kill(lastPid, 0); } catch { aliveAfter = false; }
+  assert.equal(aliveAfter, false, `fixture process ${lastPid} survived server shutdown`);
+  await rm(workdir, { recursive: true, force: true }).catch(() => {});
+}, { timeout: 30_000 });

tests/sleek-chat.acceptance.mjs

@@ -24,7 +24,7 @@ await page.route('**/api/agent/chat', async route => {
 
 await page.goto(appUrl);
 await page.waitForLoadState('networkidle');
-assert.equal(await page.evaluate(() => window.__TIMMY_CONFIG__.basePath), expectedBasePath);
+assert.equal(await page.locator('meta[name="timmy-base-path"]').getAttribute('content'), expectedBasePath);
 assert.equal(await page.locator('.bottom-nav .nav-btn').count(), 3, 'primary navigation must have exactly three destinations');
 assert.equal(await page.locator('main .btn-primary:visible').count(), 1, 'home must expose one dominant primary action');
 assert.equal(await page.locator('[data-log]:visible').count(), 1, 'manual fallback remains available once without competing styling');

tests/staging-health.test.js

@@ -91,9 +91,9 @@ test('prefixed document, manifest, and service worker stay inside the app scope'
 
   const html = await (await fetch(`${origin}/timmy-staging/`)).text();
   assert.match(html, /<base href="\/timmy-staging\/">/);
-  assert.match(html, /window\.__TIMMY_CONFIG__=/);
-  assert.match(html, /"basePath":"\/timmy-staging"/);
-  assert.match(html, /"stagingLabel":"Staging · daily-2026-08-20\.3 · ca31e6d38bec"/);
+  assert.doesNotMatch(html, /window\.__TIMMY_CONFIG__\s*=/);
+  assert.match(html, /<meta name="timmy-base-path" content="\/timmy-staging">/);
+  assert.match(html, /<meta name="timmy-staging-label" content="Staging · daily-2026-08-20\.3 · ca31e6d38bec">/);
 
   const manifest = await (await fetch(`${origin}/timmy-staging/manifest.webmanifest`)).json();
   assert.equal(manifest.start_url, '/timmy-staging/');
@@ -109,7 +109,7 @@ test('agent cookie is constrained to the normalized base path', async t => {
   const { origin } = await startServer(t, {
     TIMMY_BASE_PATH: '/timmy-staging/',
     TIMMY_AGENT_ENABLED: 'true',
-    TIMMY_AGENT_ACCESS_TOKEN: 'integration-access-code-2026',
+    TIMMY_AGENT_ACCESS_TOKEN: 'test-integration-access-code-2026',
     TIMMY_PUBLIC_ORIGIN: '__ORIGIN__',
     TIMMY_AGENT_WORKDIR: workdir,
     TIMMY_HERMES_COMMAND: hermesFixture,
@@ -119,7 +119,7 @@ test('agent cookie is constrained to the normalized base path', async t => {
   const response = await fetch(`${origin}/timmy-staging/api/agent/unlock`, {
     method: 'POST',
     headers: { 'content-type': 'application/json', origin, 'sec-fetch-site': 'same-origin' },
-    body: JSON.stringify({ accessCode: 'integration-access-code-2026' }),
+    body: JSON.stringify({ accessCode: 'test-integration-access-code-2026' }),
   });
   assert.equal(response.status, 200);
   assert.match(response.headers.get('set-cookie'), /; Path=\/timmy-staging\//);