@love-moon/conductor-cli 0.7.5 → 0.7.7

package/src/daemon.js

@@ -3,6 +3,7 @@ import path from "node:path";
 import os from "node:os";
 import { createRequire } from "node:module";
 import { spawn, spawnSync } from "node:child_process";
+import { randomUUID } from "node:crypto";
 import { fileURLToPath } from "node:url";
 
 import dotenv from "dotenv";
@@ -14,9 +15,15 @@ import {
   loadConfig,
   ConfigFileNotFound,
   ProjectContext,
+  DurableUpstreamOutboxStore,
 } from "@love-moon/conductor-sdk";
 import { DaemonLogCollector } from "./log-collector.js";
 import { envForExplicitConfigFile } from "./config-env.js";
+import {
+  materializeConductorPathEnv,
+  resolveConductorConfigPath,
+  resolveConductorHome,
+} from "./conductor-paths.js";
 import { createAiManagerHandlers, handleAiManagerRequest } from "./ai-manager-handlers.js";
 import {
   CUSTOM_COMMANDS_CAPABILITY,
@@ -53,7 +60,9 @@ import {
 import {
   maskHandoffUrlForLogs,
   maskErrorForLogs,
+  redactSecretsForLogs,
 } from "./handoff-log-mask.js";
+import { StringDecoder } from "node:string_decoder";
 
 dotenv.config();
 
@@ -62,8 +71,6 @@ const __dirname = path.dirname(__filename);
 const PACKAGE_ROOT = path.join(__dirname, "..");
 const moduleRequire = createRequire(import.meta.url);
 const CLI_PATH = path.resolve(PACKAGE_ROOT, "bin", "conductor-fire.js");
-const DAEMON_LOG_DIR = path.join(os.homedir(), ".conductor", "logs");
-const DAEMON_LOG_PATH = path.join(DAEMON_LOG_DIR, "conductor-daemon.log");
 const CLI_VERSION = (() => {
   try {
     return JSON.parse(fs.readFileSync(path.join(PACKAGE_ROOT, "package.json"), "utf-8")).version;
@@ -71,6 +78,14 @@ const CLI_VERSION = (() => {
     return "unknown";
   }
 })();
+
+export function resolveDaemonLogPaths(env = process.env) {
+  const logDir = path.join(resolveConductorHome(env), "logs");
+  return {
+    logDir,
+    logPath: path.join(logDir, "conductor-daemon.log"),
+  };
+}
 const PLAN_LIMIT_MESSAGES = {
   manual_fire_active_task: "Free plan limit reached: only 1 active fire task is allowed.",
   app_active_task: "Free plan limit reached: only 1 active app task is allowed.",
@@ -119,8 +134,9 @@ export function probePtyTaskCapability({
 
 function appendDaemonLog(line) {
   try {
-    fs.mkdirSync(DAEMON_LOG_DIR, { recursive: true });
-    fs.appendFileSync(DAEMON_LOG_PATH, line);
+    const { logDir, logPath } = resolveDaemonLogPaths();
+    fs.mkdirSync(logDir, { recursive: true });
+    fs.appendFileSync(logPath, line);
   } catch {
     // ignore file log errors
   }
@@ -156,8 +172,7 @@ function sleepSync(ms) {
 
 function getUserConfig(configFilePath) {
   try {
-    const home = os.homedir();
-    const configPath = configFilePath || path.join(home, ".conductor", "config.yaml");
+    const configPath = resolveConductorConfigPath(configFilePath);
     if (fs.existsSync(configPath)) {
       const content = fs.readFileSync(configPath, "utf8");
       const parsed = yaml.load(content);
@@ -179,7 +194,7 @@ function getUserConfig(configFilePath) {
 //
 // Resolution order:
 //   1. CONDUCTOR_FIRE_TMUX_MODE env var ("1"/"true"/"on" enable, "0"/"false"/"off" disable)
-//   2. fire_tmux_mode boolean in ~/.conductor/config.yaml
+//   2. fire_tmux_mode boolean in the resolved Conductor config.yaml
 //   3. Default: false
 function getFireTmuxModeEnabled(userConfig) {
   const rawEnv = process.env.CONDUCTOR_FIRE_TMUX_MODE;
@@ -436,7 +451,7 @@ function normalizeOptionalString(value) {
 // Re-export the handoff-URL masking helpers so existing external imports
 // keep working. Implementation lives in a dependency-free module so unit
 // tests can import it without pulling in conductor-sdk and friends.
-export { maskHandoffUrlForLogs, maskErrorForLogs };
+export { maskHandoffUrlForLogs, maskErrorForLogs, redactSecretsForLogs };
 
 function normalizeTerminalResumeStrategy(value) {
   const normalized = normalizeOptionalString(value);
@@ -617,6 +632,52 @@ function stripPtyTaskScopedEnv(source) {
   return env;
 }
 
+/**
+ * Purge terminal `task_status_update` events left undelivered by a previous run
+ * of `taskId` in `taskDir`, before a restart re-uses that same directory.
+ *
+ * The fire's durable upstream outbox is stored under the fire's cwd, keyed by
+ * the `task:<id>` delivery scope. An in-place restart intentionally re-uses the
+ * cwd, so without this purge the new run flushes the old run's KILLED/COMPLETED
+ * event on startup and kills the task it just resumed. Best-effort: a restart
+ * must never fail because of outbox bookkeeping.
+ */
+function dropSupersededTerminalStatusEvents(taskDir, taskId) {
+  if (!taskDir || !taskId) return;
+  try {
+    const store = DurableUpstreamOutboxStore.forProjectPath(taskDir, `task:${taskId}`);
+    // Distinguish "the purge failed" from "the purge does not exist here".
+    // The CLI loads the INSTALLED copy of conductor-sdk, not this repo's
+    // source, so an un-rebuilt or mismatched package silently lacks this
+    // method — and a bare try/catch would swallow the resulting TypeError
+    // exactly like a benign fs error, leaving every restart unprotected with
+    // no way to tell from the log. Say so explicitly instead. We still do not
+    // throw: an unprotected restart usually succeeds, whereas refusing to
+    // spawn would break restart outright.
+    if (typeof store?.dropPendingTerminalStatusEvents !== "function") {
+      logError(
+        `Cannot purge superseded terminal status events for task ${taskId}: the installed ` +
+          `@love-moon/conductor-sdk has no DurableUpstreamOutboxStore.dropPendingTerminalStatusEvents. ` +
+          `This restart is unprotected — a terminal status left by the previous run may kill it. ` +
+          `Rebuild and reinstall the SDK (make install-cli).`,
+      );
+      return;
+    }
+    const dropped = store.dropPendingTerminalStatusEvents();
+    if (dropped.length > 0) {
+      log(
+        `Dropped ${dropped.length} superseded terminal status event(s) for task ${taskId} before restart: ${dropped
+          .map((entry) => `${entry.payload?.status ?? "?"}@${entry.createdAt}`)
+          .join(", ")}`,
+      );
+    }
+  } catch (error) {
+    logError(
+      `Failed to purge superseded terminal status events for task ${taskId}: ${error?.message || error}`,
+    );
+  }
+}
+
 function buildPtyTaskEnv(baseEnv = process.env, launchEnv = {}) {
   const parentEnv = stripPtyTaskScopedEnv(baseEnv);
   const taskLaunchEnv = stripPtyTaskScopedEnv(launchEnv);
@@ -669,10 +730,15 @@ export function startDaemon(config = {}, deps = {}) {
   };
 
   let fileConfig;
+  const materializedConductorPathEnv = materializeConductorPathEnv(
+    config.CONFIG_FILE,
+    process.env,
+  );
+  const effectiveConfigPath = materializedConductorPathEnv.CONDUCTOR_CONFIG;
   const configFileEnv = envForExplicitConfigFile(config.CONFIG_FILE, process.env);
   try {
     fileConfig = loadConfig(config.CONFIG_FILE, { env: configFileEnv });
-    log(`Loaded config from ${config.CONFIG_FILE || "~/.conductor/config.yaml"}`);
+    log(`Loaded config from ${effectiveConfigPath}`);
   } catch (err) {
     if (!(err instanceof ConfigFileNotFound)) {
       log(`Failed to load config: ${err.message}`);
@@ -712,7 +778,7 @@ export function startDaemon(config = {}, deps = {}) {
     os.hostname()
   ).trim();
   if (!AGENT_NAME) {
-    logError("Daemon name is required. Set daemon_name in ~/.conductor/config.yaml or CONDUCTOR_DAEMON_NAME.");
+    logError(`Daemon name is required. Set daemon_name in ${effectiveConfigPath} or CONDUCTOR_DAEMON_NAME.`);
     return exitAndReturn(1);
   }
   const homeDir = process.env.HOME || os.homedir() || "/tmp";
@@ -811,6 +877,11 @@ export function startDaemon(config = {}, deps = {}) {
   const symlinkSyncFn = deps.symlinkSync || fs.symlinkSync;
   const unlinkSyncFn = deps.unlinkSync || fs.unlinkSync;
   const renameSyncFn = deps.renameSync || fs.renameSync;
+  // Used to recover a crashed fire's output from its log file when the daemon
+  // could not observe the process directly (tmux mode).
+  const openSyncFn = deps.openSync || fs.openSync;
+  const readSyncFn = deps.readSync || fs.readSync;
+  const closeSyncFn = deps.closeSync || fs.closeSync;
   const createWriteStreamFn = deps.createWriteStream || fs.createWriteStream;
   const fetchFn = deps.fetch || fetch;
   const createRtcPeerConnection = deps.createRtcPeerConnection || null;
@@ -895,6 +966,231 @@ export function startDaemon(config = {}, deps = {}) {
     return `${buildFireTmuxSessionPrefix(taskId)}${uniq}`;
   }
 
+  // Observability for spawned fires (RFC: fork-spawn black box).
+  //
+  // When a forked/branched task's backend dies during startup, the daemon
+  // previously reported a bare `exited with code N` and wrote nothing to the
+  // daemon log, so the real cause (backend auth failure, missing CLI, tmux
+  // launch error, …) was unrecoverable after the fact — even with DB access
+  // the only artifact was a generic `fire_exit`. We keep a bounded tail of the
+  // child's output so an abnormal exit can name its own cause.
+  //
+  // The tail is masked with `maskHandoffUrlForLogs` before it reaches any log
+  // or status summary: the handoff prompt embeds a share token, and a backend
+  // that echoes its argv on failure would otherwise leak a read-grant for the
+  // entire transcript into the daemon log and the task status summary.
+  const CHILD_OUTPUT_CAPTURE_LIMIT = 4000;
+  const CHILD_OUTPUT_SUMMARY_LIMIT = 400;
+
+  // Sentinel appended to a tmux-hosted fire's log by the wrapper shell (see
+  // `spawnFireProcess`). It is the *only* channel through which the daemon
+  // can learn the exit code of a process it does not own. The full marker is
+  // `[conductor-fire-exit:<per-spawn nonce>] code=<n>`.
+  const FIRE_EXIT_MARKER_PREFIX = "[conductor-fire-exit:";
+
+  const escapeForRegExp = (value) => String(value).replace(/[.*+?^${}()|[\]\\]/g, "\\$&");
+
+  // Per-spawn nonce embedded in the marker. Without it the marker is a fixed
+  // string that anything writing to the log can forge — and the log is a
+  // verbatim copy of the fire's stdout. A fire that merely *prints* the
+  // literal (an agent task reading a conductor.log, or editing this file)
+  // would plant `[conductor-fire-exit] code=0` in its own log; if that fire
+  // were then SIGKILLed, leaving no genuine marker, the reaper would read the
+  // forged one and report COMPLETED for a task that was killed. Dogfooding
+  // this repo makes that near-certain rather than theoretical.
+  //
+  // The nonce also means a previous run's marker can never be mistaken for
+  // this run's, independently of the `logStartOffset` watermark.
+  function buildFireExitMarkerToken() {
+    return randomUUID().replace(/-/g, "").slice(0, 12);
+  }
+
+  // Last exit code recorded by *this run's* wrapper shell in `raw`, or null
+  // when the marker is absent (fire was SIGKILLed / the tmux server died
+  // before the wrapper could run). Anchored at line start so it cannot match
+  // mid-line inside quoted output, and scoped by the run's nonce.
+  function parseFireExitCode(raw, markerToken) {
+    if (!raw || !markerToken) return null;
+    const pattern = new RegExp(
+      `^${escapeForRegExp(FIRE_EXIT_MARKER_PREFIX)}${escapeForRegExp(markerToken)}\\] code=(\\d+)`,
+      "gm",
+    );
+    let match = null;
+    let candidate;
+    // Scan for the *last* match rather than the first: a fresh RegExp per
+    // call, because a shared /g instance carries `lastIndex` between calls.
+    while ((candidate = pattern.exec(raw)) !== null) {
+      match = candidate;
+    }
+    if (!match) return null;
+    const code = Number(match[1]);
+    return Number.isFinite(code) ? code : null;
+  }
+
+  // Read the last `limit` bytes of a log file, never crossing below
+  // `minOffset`. The floor matters because a task's log file is opened with
+  // flags "a" and is therefore *reused* across in-place restarts: without it,
+  // a previous run's trailing bytes (including its exit marker) would be
+  // attributed to the current run. Callers that don't care pass minOffset 0.
+  function readLogTailRaw(logPath, { limit = CHILD_OUTPUT_CAPTURE_LIMIT, minOffset = 0 } = {}) {
+    if (!logPath) return "";
+    try {
+      const stat = statSyncFn(logPath);
+      const size = Number(stat?.size) || 0;
+      // A file smaller than the watermark was truncated or rotated out from
+      // under us, so the watermark no longer refers to anything. Honouring it
+      // would return "" for this record forever — which the reaper reads as
+      // "no exit marker", i.e. a fabricated hard death for a task that may
+      // have finished cleanly. Fall back to reading whatever is there.
+      const floor = size < minOffset ? 0 : Math.max(0, Number(minOffset) || 0);
+      const start = Math.max(floor, size - limit);
+      if (size <= start) return "";
+      const fd = openSyncFn(logPath, "r");
+      try {
+        const length = size - start;
+        const buf = Buffer.alloc(length);
+        readSyncFn(fd, buf, 0, length, start);
+        return buf.toString("utf8");
+      } finally {
+        closeSyncFn(fd);
+      }
+    } catch {
+      return "";
+    }
+  }
+
+  // Size of a log file, or null when it does not exist / cannot be read.
+  // The null case is load-bearing for the reaper: `tee -a` creates the file
+  // the moment it opens it, so a *missing* file means the wrapper never had
+  // a writable log at all (bad cwd, unwritable project dir) — as opposed to
+  // an empty-but-present file, which means the fire really did die before
+  // writing anything.
+  function readLogFileSize(logPath) {
+    if (!logPath) return null;
+    try {
+      return Number(statSyncFn(logPath)?.size) || 0;
+    } catch {
+      return null;
+    }
+  }
+
+  // Current size of a log file, or 0 when it doesn't exist / can't be read.
+  // Sampled just before a spawn so later tail reads can be floored at "what
+  // this run wrote".
+  function readLogSize(logPath) {
+    return readLogFileSize(logPath) ?? 0;
+  }
+
+  // How far back to hunt for this run's exit marker, and in what stride.
+  // Bounded so a huge log can never turn one sweep into an unbounded read.
+  const FIRE_EXIT_MARKER_SEARCH_LIMIT = 8 * 1024 * 1024;
+  const FIRE_EXIT_MARKER_SEARCH_CHUNK = 64 * 1024;
+
+  // Find this run's exit code by scanning *backwards* from EOF for its nonce.
+  //
+  // Reading only the last few KB would be wrong: a task's log is not private.
+  // Branch/fork tasks deliberately share a worktree — and therefore a single
+  // `conductor.log` — and a task with no worktree config falls back to the
+  // project directory, so every task in the project appends to the same file.
+  // A neighbouring fire that prints a few KB between our exit and the next
+  // reaper sweep would push our marker out of a fixed tail window. The reaper
+  // would then see "no marker", conclude the fire died hard, and report
+  // KILLED for a task that finished cleanly — quoting the *neighbour's*
+  // output as the cause of death. The marker is this run's identity, not a
+  // property of where it happens to sit in a shared stream, so search for it.
+  function findFireExitCode(logPath, { minOffset = 0, markerToken = "" } = {}) {
+    if (!logPath || !markerToken) return null;
+    let size;
+    try {
+      size = Number(statSyncFn(logPath)?.size) || 0;
+    } catch {
+      return null;
+    }
+    // A file shorter than the watermark was truncated/rotated; the offset no
+    // longer refers to anything, so search the whole file rather than nothing.
+    const floor = size < minOffset ? 0 : Math.max(0, Number(minOffset) || 0);
+    const searchFloor = Math.max(floor, size - FIRE_EXIT_MARKER_SEARCH_LIMIT);
+    let fd;
+    try {
+      fd = openSyncFn(logPath, "r");
+    } catch {
+      return null;
+    }
+    try {
+      let end = size;
+      // Overlap successive chunks by enough to cover a marker split across a
+      // boundary, so a line straddling two reads is still found.
+      const overlap = FIRE_EXIT_MARKER_PREFIX.length + markerToken.length + 32;
+      while (end > searchFloor) {
+        const start = Math.max(searchFloor, end - FIRE_EXIT_MARKER_SEARCH_CHUNK);
+        const length = end - start;
+        const buf = Buffer.alloc(length);
+        readSyncFn(fd, buf, 0, length, start);
+        const code = parseFireExitCode(buf.toString("utf8"), markerToken);
+        if (code !== null) return code;
+        if (start <= searchFloor) break;
+        end = start + overlap;
+      }
+      return null;
+    } catch {
+      return null;
+    } finally {
+      try {
+        closeSyncFn(fd);
+      } catch {
+        // best effort
+      }
+    }
+  }
+
+  // Collapse, redact and clamp a raw output tail so it is safe to put in a
+  // daemon log line or a persisted task status summary.
+  function sanitizeOutputTail(raw, limit = CHILD_OUTPUT_SUMMARY_LIMIT) {
+    // Collapse first, then redact: the mask patterns stop at whitespace, so
+    // a secret split across a newline would otherwise only be half-matched.
+    const collapsed = String(raw || "").replace(/\s+/g, " ").trim();
+    const safe = redactSecretsForLogs(collapsed, [AGENT_TOKEN]).trim();
+    if (!safe) return "";
+    // slice(-(limit - 1)) keeps the ellipsis inside the documented budget.
+    return safe.length > limit ? `…${safe.slice(-(limit - 1))}` : safe;
+  }
+
+  function createChildOutputCapture({ logPath = "", logStartOffset = 0 } = {}) {
+    let buffer = "";
+    // Decode across chunk boundaries: a raw per-chunk toString("utf8") splits
+    // multi-byte characters whenever a chunk ends mid-sequence, which would
+    // put mojibake into the persisted status summary.
+    const decoder = new StringDecoder("utf8");
+    const append = (chunk) => {
+      const text =
+        typeof chunk === "string" ? chunk : decoder.write(Buffer.from(chunk));
+      if (!text) return;
+      buffer += text;
+      if (buffer.length > CHILD_OUTPUT_CAPTURE_LIMIT) {
+        buffer = buffer.slice(-CHILD_OUTPUT_CAPTURE_LIMIT);
+      }
+    };
+    // Attaching an extra `data` listener is safe alongside `.pipe()`: pipe
+    // keeps the stream in flowing mode and additional listeners observe the
+    // same chunks without consuming them.
+    const attach = (stream) => {
+      if (stream && typeof stream.on === "function") {
+        stream.on("data", append);
+      }
+    };
+
+    // In tmux mode the daemon's child is the `tmux new-session` client, and
+    // the fire's own output is redirected to `logPath` *inside* the session
+    // (`… 2>&1 | tee -a <logPath>`). The in-memory buffer therefore only ever
+    // holds tmux's own errors. When it is empty, fall back to the tail of the
+    // log file so the backend's actual crash output is still reported.
+    const readLogTail = () => readLogTailRaw(logPath, { minOffset: logStartOffset });
+
+    const tail = (limit = CHILD_OUTPUT_SUMMARY_LIMIT) =>
+      sanitizeOutputTail(buffer.trim() ? buffer : readLogTail(), limit);
+    return { attach, append, tail };
+  }
+
   // Spawn the Fire CLI either directly (default) or inside a detached tmux
   // session (when FIRE_TMUX_MODE_ACTIVE). In tmux mode the returned `child`
   // is the short-lived `tmux new-session` client; once it exits with code 0
@@ -908,7 +1204,7 @@ export function startDaemon(config = {}, deps = {}) {
         env,
         stdio: ["inherit", "pipe", "pipe"],
       });
-      return { child, tmuxSession: null };
+      return { child, tmuxSession: null, exitMarkerToken: "" };
     }
 
     const sessionName = buildFireTmuxSessionName(taskId);
@@ -919,9 +1215,37 @@ export function startDaemon(config = {}, deps = {}) {
     // via `tmux a -t <session>` for live observation is useless. With
     // `tee` the same bytes go to both the pane (visible to whoever
     // attaches) and the log file (preserved for offline inspection).
-    const redirectedCommand = logPath
-      ? `${innerCommandParts.join(" ")} 2>&1 | tee -a ${shellQuoteForBash(logPath)}`
-      : innerCommandParts.join(" ");
+    //
+    // The trailing exit-marker is what makes a death *inside* the session
+    // observable. The daemon's child is only the `tmux new-session` client,
+    // so once the session exists the daemon has no handle on Fire and never
+    // sees its exit code. `${PIPESTATUS[0]}` recovers Fire's own status from
+    // the pipeline (plain `$?` would be tee's), and appending it to the log
+    // lets the liveness reaper tell "finished normally" from "crashed" —
+    // without which it could only ever guess, and guessing KILLED would
+    // mis-report successful tasks as failures.
+    //
+    // No `exec` in this branch: the wrapper bash must outlive Fire to write
+    // the marker. When Fire is SIGKILLed (or the tmux server dies) the
+    // marker is simply absent, which the reaper reads as "died hard" — the
+    // correct conclusion.
+    //
+    // Each branch owns its own `exec` (or absence of one) and the result is
+    // passed to `bash -c` verbatim. Do NOT re-wrap it in `exec` at the call
+    // site: `exec exec …` is a bash error ("exec: exec: not found", 127),
+    // which in tmux mode means Fire never starts while the tmux client still
+    // exits 0 — a task that hangs at `running` with nothing in the log.
+    const quotedLogPath = logPath ? shellQuoteForBash(logPath) : "";
+    // `\n` before the marker guarantees it starts its own line even when the
+    // fire's last write had no trailing newline — the reader anchors on `^`.
+    const exitMarkerToken = logPath ? buildFireExitMarkerToken() : "";
+    const shellCommand = logPath
+      ? `${innerCommandParts.join(" ")} 2>&1 | tee -a ${quotedLogPath}; ` +
+        `__conductor_fire_code=\${PIPESTATUS[0]}; ` +
+        `printf '\\n${FIRE_EXIT_MARKER_PREFIX}${exitMarkerToken}] code=%s\\n' ` +
+        `"$__conductor_fire_code" >> ${quotedLogPath}; ` +
+        `exit $__conductor_fire_code`
+      : `exec ${innerCommandParts.join(" ")}`;
 
     // Build `-e KEY=VALUE` flags for the new session.
     //
@@ -969,7 +1293,7 @@ export function startDaemon(config = {}, deps = {}) {
       cwd,
       "bash",
       "-c",
-      `exec ${redirectedCommand}`,
+      shellCommand,
     ];
     log(`Spawning Fire via tmux: session=${sessionName} cwd=${cwd}`);
     const child = spawnFn("tmux", tmuxArgs, {
@@ -981,7 +1305,7 @@ export function startDaemon(config = {}, deps = {}) {
     if (typeof child.unref === "function") {
       child.unref();
     }
-    return { child, tmuxSession: sessionName };
+    return { child, tmuxSession: sessionName, exitMarkerToken };
   }
 
   // Async probe: does the named tmux session still exist? Resolves to a
@@ -1000,34 +1324,45 @@ export function startDaemon(config = {}, deps = {}) {
     }
     return 5000;
   })();
-  function tmuxSessionExists(sessionName) {
+  // Detailed probe: resolves `{ alive, conclusive }`.
+  //
+  // `conclusive` distinguishes "tmux answered, and the session is gone"
+  // (has-session exited non-zero) from "we never got an answer" (spawn error,
+  // tmux binary missing, wedged server hitting the timeout). Both used to
+  // collapse into a bare `false`, which was fine when the only consequence
+  // was dropping a bookkeeping entry. It is NOT fine now that the reaper
+  // turns "not alive" into an authoritative KILLED with a cause of death: one
+  // transient tmux hiccup would otherwise declare every live tmux task dead,
+  // each with a confidently wrong "disappeared without an exit marker".
+  function probeTmuxSession(sessionName) {
     return new Promise((resolve) => {
       if (!sessionName) {
-        resolve(false);
+        resolve({ alive: false, conclusive: false });
         return;
       }
       let settled = false;
       let probe = null;
       let timer = null;
-      const settle = (alive) => {
+      const settle = (alive, conclusive) => {
         if (settled) return;
         settled = true;
         if (timer) {
           clearTimeout(timer);
           timer = null;
         }
-        resolve(alive);
+        resolve({ alive, conclusive });
       };
       try {
         probe = spawnFn("tmux", ["has-session", "-t", sessionName], {
           stdio: "ignore",
         });
-        probe.on("exit", (code) => settle(code === 0));
-        probe.on("error", () => settle(false));
+        // tmux answered: exit 0 = alive, non-zero = genuinely no such session.
+        probe.on("exit", (code) => settle(code === 0, true));
+        // Could not run tmux at all — says nothing about the session.
+        probe.on("error", () => settle(false, false));
         timer = setTimeout(() => {
-          // Probe took too long — assume the session state is unknown,
-          // treat as "not alive" (so the reaper falls back to safe cleanup),
-          // and best-effort kill the stuck child so it doesn't pile up.
+          // Probe took too long — the session state is unknown. Best-effort
+          // kill the stuck child so it doesn't pile up.
           try {
             if (probe && typeof probe.kill === "function") {
               probe.kill("SIGKILL");
@@ -1038,45 +1373,289 @@ export function startDaemon(config = {}, deps = {}) {
           logError(
             `tmux has-session probe timed out after ${TMUX_PROBE_TIMEOUT_MS}ms for session ${sessionName}`,
           );
-          settle(false);
+          settle(false, false);
         }, TMUX_PROBE_TIMEOUT_MS);
         if (typeof timer.unref === "function") {
           timer.unref();
         }
       } catch {
-        settle(false);
+        settle(false, false);
       }
     });
   }
 
-  // Walk every tmux-mode entry in `activeTaskProcesses` and remove the ones
-  // whose tmux session no longer exists. We don't (and can't reliably)
-  // observe the inner Fire process exit when we never owned it as a child,
-  // so this best-effort sweep is what keeps the active map from leaking
-  // across long daemon lifetimes.
+  // Boolean form, for the callers that only gate local bookkeeping or a
+  // best-effort kill and are happy to treat "unknown" as "not alive".
+  async function tmuxSessionExists(sessionName) {
+    return (await probeTmuxSession(sessionName)).alive;
+  }
+
+  const BACKEND_STATUS_PROBE_TIMEOUT_MS = (() => {
+    const explicit = Number(config.BACKEND_STATUS_PROBE_TIMEOUT_MS);
+    if (Number.isFinite(explicit) && explicit > 0) {
+      return explicit;
+    }
+    return 10_000;
+  })();
+
+  // Current backend-side status of a task, lowercased, or null when it can't
+  // be determined (HTTP error, unreachable backend, malformed payload).
   //
-  // Theoretical startup race (intentionally not guarded against):
-  //   `spawnFireProcess` returns synchronously, and we set the active
-  //   record before the spawned `tmux new-session -d` client has actually
-  //   exited. There is therefore a microsecond-scale window in which an
-  //   active record exists but `tmux has-session` may return false because
-  //   the session has not finished registering with the tmux server. With
-  //   the default 30s poll interval the chance of hitting this window is
-  //   ~negligible, and even when hit Fire's own websocket connection
-  //   subsequently overwrites any stale terminal status the daemon
-  //   reports. If this ever shows up in production, add a `createdAt`
-  //   timestamp to the record and a grace period here.
+  // Hard timeout, for the same reason `tmuxSessionExists` has one: this call
+  // is awaited inside the reaper sweep, and the sweep's re-entrancy latch is
+  // only released in a `finally`. A backend that black-holes the connection
+  // would otherwise leave the latch stuck forever — permanently disabling the
+  // only observer of in-session deaths, which is the exact failure this whole
+  // change exists to prevent.
+  async function fetchBackendTaskStatus(taskId) {
+    if (!BACKEND_HTTP || !AGENT_TOKEN || !taskId) return null;
+    // The timeout must cover reading the BODY, not just the headers. `fetch`
+    // resolves as soon as headers arrive, so wrapping only that call leaves
+    // `response.json()` unbounded: a backend that answers 200 and then stalls
+    // the body (half-open proxy, hung route) parks this await forever, the
+    // sweep's re-entrancy latch never clears, and the only observer of
+    // in-session deaths is permanently disabled. `markBackendHttpSuccess` is
+    // likewise deferred until the body actually parsed — crediting the
+    // watchdog for a response we could not read would be a lie.
+    const controller = typeof AbortController !== "undefined" ? new AbortController() : null;
+    try {
+      const status = await withTimeout(
+        (async () => {
+          const response = await fetchFn(`${BACKEND_HTTP}/api/tasks/${taskId}`, {
+            method: "GET",
+            headers: {
+              Authorization: `Bearer ${AGENT_TOKEN}`,
+              Accept: "application/json",
+            },
+            signal: controller?.signal,
+          });
+          if (!response?.ok) return null;
+          const task = await response.json();
+          markBackendHttpSuccess();
+          return String(task?.status || "").trim().toLowerCase() || null;
+        })(),
+        BACKEND_STATUS_PROBE_TIMEOUT_MS,
+        `task status probe for ${taskId}`,
+      );
+      return status;
+    } catch (error) {
+      // Release the socket; withTimeout only stops us waiting, it cannot
+      // cancel the request on its own.
+      try {
+        controller?.abort();
+      } catch {
+        // best effort
+      }
+      logError(`Failed to query backend status for task ${taskId}: ${error?.message || error}`);
+      return null;
+    }
+  }
+
+  const TERMINAL_BACKEND_TASK_STATUSES = new Set(["completed", "killed"]);
+
+  // A tmux session vanished. Decide what — if anything — to tell the backend.
+  //
+  // This is the fix for "fire dies inside its tmux session and nobody
+  // notices". The daemon's child was only the `tmux new-session` client,
+  // which exited 0 long ago, so there is no exit event to observe. Without a
+  // report here the task sits at `running` until the next reconcile sweep
+  // collects it, and reconcile's `PATCH {status:"killed"}` is rewritten by
+  // the task route into `killing` → `killed`, which the upstream commit path
+  // reads as `killedReason = "user_stopped"`. The user never pressed stop,
+  // and the real cause is lost.
+  //
+  // Two hazards make a naive "session gone → report KILLED" wrong, and both
+  // are handled below:
+  //   1. A session also disappears when fire finished *successfully*.
+  //      Reporting KILLED unconditionally would rewrite completed tasks as
+  //      failures. We therefore classify from the exit marker the wrapper
+  //      shell appends to the log, not from the disappearance itself.
+  //   2. Fire usually reports its own terminal status over its own
+  //      websocket. `commitTaskStatusUpdate` has no terminal→terminal guard,
+  //      so a late KILLED from us would clobber a COMPLETED from fire. We
+  //      ask the backend first and stay silent when the task already reached
+  //      a terminal state.
+  //
+  // Note on `suppressedExitStatusReports`: it is deliberately NOT consulted
+  // here. Every path that sets it (refresh_session_inplace via
+  // `stopActiveTaskProcess`) removes the active record synchronously, so the
+  // reaper can never see a record it applies to — but the flag itself is
+  // never cleared in tmux mode, because the tmux client's exit handler
+  // returns early and only the non-early path consumes it. Honouring a flag
+  // that outlives its task would silence a later, unrelated death. The
+  // backend status pre-check below is the guard that actually matters.
+  async function reportDeadTmuxSessionStatus(taskId, record) {
+    if (!record?.projectId) {
+      logError(`Cannot report terminal status for task ${taskId}: no project id on the active record`);
+      return;
+    }
+    // The exit marker only exists because the wrapper shell writes it to
+    // `logPath`. Without one there is no evidence at all, and "no marker"
+    // would be misread as "died hard" — reporting every clean finish as
+    // KILLED. Staying silent restores the old blind spot for this task only,
+    // which is strictly better than manufacturing a wrong cause of death.
+    if (!record.logPath) {
+      logError(
+        `Cannot classify the end of task ${taskId}: no log path on the active record, so no exit marker exists`,
+      );
+      return;
+    }
+    // Same reasoning, one level down. `tee -a` creates the log the instant it
+    // opens it, so a missing file means the wrapper could never write there
+    // (unwritable or vanished cwd) — and `tee` failing does NOT stop the fire,
+    // which runs to completion while the tmux client still exits 0. Treating
+    // that absence as "no exit marker" would report a green task as KILLED
+    // with an invented "killed or OOM" cause. An empty-but-present file is
+    // different: the fire really did die before writing anything.
+    if (readLogFileSize(record.logPath) === null) {
+      logError(
+        `Cannot classify the end of task ${taskId}: log file ${record.logPath} is missing, ` +
+          `so the absence of an exit marker proves nothing`,
+      );
+      return;
+    }
+
+    const rawTail = readLogTailRaw(record.logPath, { minOffset: record.logStartOffset || 0 });
+    // Search the file for the marker rather than hoping it is still inside
+    // the tail window — see `findFireExitCode` for why a shared log makes the
+    // tail unreliable. The tail is still what feeds the human-readable
+    // summary; only the *verdict* needs the exhaustive lookup.
+    const exitCode = findFireExitCode(record.logPath, {
+      minOffset: record.logStartOffset || 0,
+      markerToken: record.exitMarkerToken,
+    });
+    const lifetimeMs = record.spawnedAtMs ? Date.now() - record.spawnedAtMs : null;
+
+    // Classification. `null` exit code means the wrapper shell never got to
+    // write the marker — SIGKILL, OOM kill, or a tmux server crash.
+    const isKilled = exitCode === null || exitCode !== 0;
+    const status = isKilled ? "KILLED" : "COMPLETED";
+    //
+    // The success summary deliberately is NOT the bare word "completed".
+    // The web side treats a summary that merely restates the status as
+    // trivial and drops it — but only when it has to synthesize the event
+    // id. We send our own id (for idempotency), which bypasses that filter,
+    // so a bare "completed" would be persisted and would overwrite
+    // `latest_status_summary` with a word that says nothing. Naming *how* we
+    // found out keeps the event worth its row: it tells the next reader that
+    // fire never published its own status.
+    const baseSummary =
+      exitCode === null
+        ? "fire tmux session disappeared without an exit marker (killed or OOM)"
+        : exitCode === 0
+          ? "completed; detected by the daemon after the tmux session ended (fire never reported it)"
+          : exitCode === 130 || exitCode === 143
+            ? `terminated (exit code ${exitCode})`
+            : `exited with code ${exitCode}`;
+
+    // Ask the backend before overwriting anything: fire normally reports its
+    // own terminal status and we must not downgrade a success.
+    const backendStatus = await fetchBackendTaskStatus(taskId);
+    if (backendStatus && TERMINAL_BACKEND_TASK_STATUSES.has(backendStatus)) {
+      log(
+        `Tmux session ${record.tmuxSession} for task ${taskId} ended; backend already ${backendStatus}, no report needed`,
+      );
+      return;
+    }
+
+    // The await above yields the event loop, and "this task looks dead" is
+    // precisely the trigger for an in-place restart. A `restart_task` landing
+    // in that window finds no active record (we deleted it), spawns a fresh
+    // fire and reports RUNNING — and our stale report would then mark the
+    // *live* replacement as killed, using the previous run's log tail. Worse,
+    // the daemon's own map would say running, so reconcile would never repair
+    // it. Re-check that the task is still absent before speaking.
+    if (activeTaskProcesses.has(taskId)) {
+      log(
+        `Task ${taskId} was restarted while its dead tmux session was being reported; dropping the stale terminal status`,
+      );
+      return;
+    }
+
+    // Strip the marker before it reaches a user-visible summary: its content
+    // is already stated by the classification above, so leaving it in just
+    // appends "[conductor-fire-exit] code=1" to "exited with code 1".
+    const outputTail = isKilled
+      ? sanitizeOutputTail(
+          rawTail.replace(
+            new RegExp(`${escapeForRegExp(FIRE_EXIT_MARKER_PREFIX)}[^\\]]*\\] code=\\d+`, "g"),
+            "",
+          ),
+        )
+      : "";
+    if (isKilled) {
+      logError(
+        `[tmux-reap] fire died inside its session task=${taskId} ` +
+          `tmux=${record.tmuxSession || "none"} exit=${exitCode === null ? "unknown" : exitCode} ` +
+          `lifetime_ms=${lifetimeMs === null ? "unknown" : lifetimeMs} log=${record.logPath || "none"} ` +
+          `backend_status=${backendStatus || "unknown"} ` +
+          `output_tail=${outputTail ? JSON.stringify(outputTail) : "<empty>"}`,
+      );
+    }
+    const summary = outputTail ? `${baseSummary}: ${outputTail}` : baseSummary;
+
+    client
+      .sendJson({
+        type: "task_status_update",
+        payload: {
+          task_id: taskId,
+          project_id: record.projectId,
+          status,
+          summary,
+          // Idempotency key. Generated per call, so it only dedupes
+          // transport-level redelivery of *this* message — not a second,
+          // independent reaper report (the record deletion above is what
+          // prevents those). It is also what makes the backend persist
+          // `summary` at all: without a client-supplied id the server
+          // synthesizes a fresh one per delivery.
+          status_event_id: randomUUID(),
+        },
+      })
+      .catch((err) => {
+        logError(
+          `Failed to report task status (${status}) for reaped tmux task ${taskId}: ${err?.message || err}`,
+        );
+      });
+  }
+
+  // Walk every tmux-mode entry in `activeTaskProcesses`, remove the ones
+  // whose tmux session no longer exists, and report a terminal status for
+  // them. We don't (and can't reliably) observe the inner Fire process exit
+  // when we never owned it as a child, so this sweep is both what keeps the
+  // active map from leaking across long daemon lifetimes *and* the only
+  // place a death inside the session can be noticed at all.
+  //
+  // Startup race (now guarded — it used to be merely theoretical):
+  //   `spawnFireProcess` returns synchronously and we set the active record
+  //   before the spawned `tmux new-session -d` client has actually exited,
+  //   so there is a window in which an active record exists but
+  //   `tmux has-session` returns false because the session has not finished
+  //   registering with the tmux server. That window was harmless while the
+  //   reaper only cleaned up local bookkeeping; now that it reports terminal
+  //   statuses, hitting it would kill a task that started fine. Records are
+  //   therefore ignored until they are `TMUX_REAP_GRACE_MS` old.
   async function reapDeadTmuxSessionsOnce() {
     const candidates = [];
+    const now = Date.now();
     for (const [taskId, record] of activeTaskProcesses.entries()) {
-      if (record?.tmuxMode && record.tmuxSession) {
-        candidates.push([taskId, record]);
-      }
+      if (!record?.tmuxMode || !record.tmuxSession) continue;
+      const spawnedAtMs = Number(record.spawnedAtMs) || 0;
+      if (spawnedAtMs && now - spawnedAtMs < TMUX_REAP_GRACE_MS) continue;
+      candidates.push([taskId, record]);
     }
     for (const [taskId, record] of candidates) {
-      const alive = await tmuxSessionExists(record.tmuxSession);
-      // Only remove the entry if it still points to the same record; a
-      // concurrent restart_task may have replaced it while we were probing.
+      const { alive, conclusive } = await probeTmuxSession(record.tmuxSession);
+      // An inconclusive probe (tmux missing, wedged server, timeout) is not
+      // evidence of death. Leave the record alone and retry next sweep rather
+      // than cleaning up — and reporting a cause of death — on a guess.
+      if (!alive && !conclusive) {
+        logError(
+          `Could not determine whether tmux session ${record.tmuxSession} for task ${taskId} is alive; leaving it untouched`,
+        );
+        continue;
+      }
+      // Only act if the entry still points to the same record; a concurrent
+      // restart_task may have replaced it while we were probing.
       if (!alive && activeTaskProcesses.get(taskId) === record) {
         log(
           `Tmux session ${record.tmuxSession} for task ${taskId} no longer exists; cleaning up activeTaskProcesses entry`,
@@ -1086,6 +1665,9 @@ export function startDaemon(config = {}, deps = {}) {
           record.stopForceKillTimer = null;
         }
         activeTaskProcesses.delete(taskId);
+        // Report *after* dropping the local entry so a slow backend round
+        // trip can't make a concurrent stop_task wait on us.
+        await reportDeadTmuxSessionStatus(taskId, record);
       }
     }
   }
@@ -1426,6 +2008,10 @@ export function startDaemon(config = {}, deps = {}) {
     }
   }
 
+  // Monotonic suffix so two symlink swaps inside one daemon process can never
+  // collide on the same temp path.
+  let symlinkSequence = 0;
+
   async function ensureTaskWorktreeSymlinks({ projectRepoRoot, projectWorkspacePath, finalCwd }) {
     const { symlinkPaths } = readProjectWorktreeSettings(projectWorkspacePath);
     for (const configuredPath of symlinkPaths) {
@@ -1439,6 +2025,27 @@ export function startDaemon(config = {}, deps = {}) {
       if (await isGitTrackedWorktreePath({ projectRepoRoot, sourcePath })) {
         continue;
       }
+
+      // Never link to a source that isn't there. `symlinkSync` does NOT
+      // require its target to exist (POSIX), so a stale `worktree.symlink`
+      // entry — e.g. `xr/android/build/local.properties`, generated locally by
+      // the IDE and never present on this machine — would otherwise make the
+      // daemon *manufacture* a dangling link on the very first worktree prep.
+      // Those links are pure liability: they break tooling that follows them,
+      // and they are what the EEXIST-on-reprepare bug below fed on.
+      //
+      // Note this is the one place where `existsSync` is the RIGHT probe:
+      // here we genuinely care whether the target resolves to something real
+      // (a source that is itself a dangling link is equally useless). The
+      // destination probe further down must use `lstat` instead, for exactly
+      // the opposite reason — see the note there.
+      if (!existsSyncFn(sourcePath)) {
+        logError(
+          `[worktree] skipping symlink for missing source: ${configuredPath} (expected at ${sourcePath})`,
+        );
+        continue;
+      }
+
       const linkPath = resolveProjectScopedPath(
         finalCwd,
         configuredPath,
@@ -1446,21 +2053,70 @@ export function startDaemon(config = {}, deps = {}) {
       );
       mkdirSyncFn(path.dirname(linkPath), { recursive: true });
 
-      if (existsSyncFn(linkPath)) {
+      // NOTE: probe with lstat, never existsSync. existsSync FOLLOWS symlinks,
+      // so a dangling link (source deleted after the worktree was created —
+      // .venv / node_modules / local.properties are all gitignored churn)
+      // reads as "missing", and the symlinkSyncFn below then throws EEXIST.
+      // That made the task permanently un-restartable.
+      let linkStat = null;
+      try {
+        linkStat = lstatSyncFn(linkPath);
+      } catch (error) {
+        if (error?.code !== "ENOENT") {
+          throw error instanceof Error ? error : new Error(String(error));
+        }
+      }
+
+      if (linkStat) {
+        if (!linkStat.isSymbolicLink()) {
+          throw new Error(
+            `worktree symlink destination already exists and is not a symlink: ${linkPath}. ` +
+              `Refusing to replace it because it may hold real data — remove it manually, ` +
+              `or drop "${configuredPath}" from worktree.symlink in .conductor/settings.yaml.`,
+          );
+        }
+        // Compare the link's TARGET, not whether that target resolves. A link
+        // that already points at the right place is correct even when the
+        // source is currently absent.
+        const currentTarget = readlinkSyncFn(linkPath);
+        const currentResolvedTarget = path.resolve(path.dirname(linkPath), currentTarget);
+        if (currentResolvedTarget === sourcePath) {
+          continue;
+        }
+        // Self-heal instead of aborting. A stale link happens whenever the
+        // project moves on disk or its workspace_path binding is edited: every
+        // pre-existing worktree then holds links to the OLD absolute path, and
+        // throwing here made every task in them permanently un-restartable.
+        //
+        // Replacing is safe precisely because this entry is a SYMLINK: it
+        // carries no data of its own, so unlinking destroys nothing. (The
+        // non-symlink case above still throws — a real file or directory here
+        // may hold user data and must never be clobbered.) The source is also
+        // known to exist at this point, thanks to the guard further up, so we
+        // are converging on a link that actually resolves.
+        log(
+          `[worktree] repointing stale symlink ${linkPath}: ${currentResolvedTarget} -> ${sourcePath}`,
+        );
+        // Atomic replace. branch/fork tasks deliberately SHARE one worktree
+        // (identity is keyed on worktreeBranch), so two preparations can run
+        // against this directory concurrently. A plain unlink+symlink leaves a
+        // window where the peer's symlinkSync hits EEXIST — reintroducing the
+        // very failure this function was fixed for. symlink-to-temp + rename
+        // has no such window: rename(2) atomically replaces the entry.
+        const tempLinkPath = `${linkPath}.conductor-tmp-${process.pid}-${symlinkSequence++}`;
+        const relativeTargetForSwap = path.relative(path.dirname(linkPath), sourcePath) || ".";
+        symlinkSyncFn(relativeTargetForSwap, tempLinkPath);
         try {
-          const stat = lstatSyncFn(linkPath);
-          if (!stat.isSymbolicLink()) {
-            throw new Error(`worktree symlink destination already exists: ${linkPath}`);
-          }
-          const currentTarget = readlinkSyncFn(linkPath);
-          const currentResolvedTarget = path.resolve(path.dirname(linkPath), currentTarget);
-          if (currentResolvedTarget === sourcePath) {
-            continue;
-          }
-          throw new Error(`worktree symlink destination already points elsewhere: ${linkPath}`);
+          renameSyncFn(tempLinkPath, linkPath);
         } catch (error) {
+          try {
+            unlinkSyncFn(tempLinkPath);
+          } catch {
+            // best effort: never mask the original failure
+          }
           throw error instanceof Error ? error : new Error(String(error));
         }
+        continue;
       }
 
       const relativeTarget = path.relative(path.dirname(linkPath), sourcePath) || ".";
@@ -2092,6 +2748,20 @@ export function startDaemon(config = {}, deps = {}) {
     return 30 * 1000;
   })();
 
+  // How long a freshly spawned tmux-mode task is exempt from the reaper.
+  // Covers the window between "we recorded the active task" and "the tmux
+  // server finished registering the session", during which `has-session`
+  // can legitimately answer false for a task that started fine. Since the
+  // reaper now reports terminal statuses, a false positive here would kill a
+  // healthy task, so the exemption is no longer optional. Tests set 0.
+  const TMUX_REAP_GRACE_MS = (() => {
+    const explicit = Number(config.TMUX_REAP_GRACE_MS);
+    if (Number.isFinite(explicit) && explicit >= 0) {
+      return explicit;
+    }
+    return 15 * 1000;
+  })();
+
   // --- Auto-update state ---
   const VERSION_CHECK_INTERVAL_MS = 6 * 60 * 60 * 1000; // 6 hours
   let lastVersionCheckAt = 0;
@@ -2144,8 +2814,8 @@ export function startDaemon(config = {}, deps = {}) {
   if (advertisedCapabilities.length > 0) {
     extraHeaders["x-conductor-capabilities"] = advertisedCapabilities.join(",");
   }
-  const aiManagerHandlers = createAiManagerHandlers({ configPath: config.CONFIG_FILE });
-  const customCommandHandlers = createCustomCommandHandlers({ configPath: config.CONFIG_FILE });
+  const aiManagerHandlers = createAiManagerHandlers({ configPath: effectiveConfigPath });
+  const customCommandHandlers = createCustomCommandHandlers({ configPath: effectiveConfigPath });
 
   const client = createWebSocketClient(sdkConfig, {
     extraHeaders,
@@ -2690,15 +3360,16 @@ export function startDaemon(config = {}, deps = {}) {
 
     let logFd = null;
     if (shouldRespawn) {
+      const { logDir: daemonLogDir, logPath: daemonLogPath } = resolveDaemonLogPaths();
       try {
-        mkdirSyncFn(DAEMON_LOG_DIR, { recursive: true });
+        mkdirSyncFn(daemonLogDir, { recursive: true });
       } catch {
         /* ignore */
       }
-      logFd = fs.openSync(DAEMON_LOG_PATH, "a");
+      logFd = fs.openSync(daemonLogPath, "a");
       if (!isBackgroundProcess) {
         log(
-          `[${reason}] Foreground daemon will be respawned in background. Logs: ${DAEMON_LOG_PATH}`
+          `[${reason}] Foreground daemon will be respawned in background. Logs: ${daemonLogPath}`
         );
       }
     }
@@ -2719,6 +3390,7 @@ export function startDaemon(config = {}, deps = {}) {
           stdio: ["ignore", logFd, logFd],
           env: {
             ...process.env,
+            ...materializedConductorPathEnv,
             CONDUCTOR_LOCK_HANDOFF_TOKEN: handoffToken,
             CONDUCTOR_LOCK_HANDOFF_FROM_PID: String(process.pid),
             CONDUCTOR_LOCK_HANDOFF_EXPIRES_AT: String(handoffExpiresAt),
@@ -4768,8 +5440,18 @@ export function startDaemon(config = {}, deps = {}) {
 
     let entry = activeTaskProcesses.get(taskId);
     if (entry?.tmuxMode && entry.tmuxSession) {
-      const alive = await tmuxSessionExists(entry.tmuxSession);
-      if (!alive) {
+      // Only a conclusive "no such session" counts as death. A wedged or
+      // missing tmux answers `false` too, and acting on that would ack the
+      // reclaim as `stale` for a fire that is still running — the backend
+      // then spawns a replacement and two fires share one worktree. It would
+      // also drop the record, so the reaper could never classify the real
+      // death later. When we cannot tell, keep the record and say "alive".
+      const { alive, conclusive } = await probeTmuxSession(entry.tmuxSession);
+      if (!alive && !conclusive) {
+        logError(
+          `Could not determine whether tmux session ${entry.tmuxSession} for task ${taskId} is alive; treating reclaim as still-alive`,
+        );
+      } else if (!alive) {
         if (activeTaskProcesses.get(taskId) === entry) {
           if (entry.stopForceKillTimer) {
             clearTimeout(entry.stopForceKillTimer);
@@ -4836,6 +5518,40 @@ export function startDaemon(config = {}, deps = {}) {
     if ((!processRecord || !processRecord.child) && !ptyRecord) {
       log(`Stop requested for task ${taskId}, but no active process found`);
       sendStopAck(false);
+      // "Nothing to stop" IS the terminal answer, and the server cannot infer
+      // it: after the app flips the row to `killing` it waits for us to report
+      // a terminal status, and a bare `stop_ack(accepted=false)` is only
+      // command bookkeeping — it never converges the task. Staying silent here
+      // is what strands a task in `killing` forever once its fire has already
+      // died (e.g. the tmux session was reaped before the user pressed Stop).
+      // Mirror the tmux stop path and publish KILLED so the row reaches a
+      // terminal state that the user can then restart from.
+      const terminalProjectId =
+        normalizeOptionalString(payload?.project_id) ||
+        normalizeOptionalString(processRecord?.projectId);
+      if (terminalProjectId) {
+        client
+          .sendJson({
+            type: "task_status_update",
+            payload: {
+              task_id: taskId,
+              project_id: terminalProjectId,
+              status: "KILLED",
+              summary: payload?.reason
+                ? `stopped (${payload.reason}); no active process`
+                : "stopped; no active process",
+            },
+          })
+          .catch((err) => {
+            logError(
+              `Failed to report task_status_update(KILLED) for inactive task ${taskId}: ${err?.message || err}`,
+            );
+          });
+      } else {
+        logError(
+          `Cannot report terminal status for inactive task ${taskId}: no project_id in stop_task payload`,
+        );
+      }
       // Even when we have no in-memory record, the task may still own a
       // tmux session (e.g. the daemon was restarted between spawn and
       // stop, or the liveness reaper removed our entry but the session
@@ -4973,6 +5689,19 @@ export function startDaemon(config = {}, deps = {}) {
         : "restart failed";
     const scrubbedError = maskErrorForLogs(error);
     const summary = `${prefix}: ${scrubbedError?.message || scrubbedError}`;
+    // Always leave a daemon-log trace. Several early rejects (unsupported
+    // backend, cwd resolution, worktree prep) return before the "Restarting
+    // task …" line is ever logged, so without this a failed branch/fork left
+    // the daemon log completely silent and only a generic `fire_exit` in the
+    // backend DB.
+    // Benign, self-explanatory outcomes (orderly shutdown, a refresh that is
+    // already in flight) are logged at normal level so they don't show up as
+    // errors in monitoring; genuine failures still go to stderr.
+    const failureText = `${scrubbedError?.message || scrubbedError}`;
+    const isBenign = /daemon shut(ting)? down|already in progress/i.test(failureText);
+    (isBenign ? log : logError)(
+      `[restart-spawn] failure task=${taskId} mode=${mode || "unknown"}: ${failureText}`,
+    );
     if (mode === "refresh_session_inplace") {
       rememberCommandRequestAckResult(requestId, false);
     }
@@ -4995,6 +5724,13 @@ export function startDaemon(config = {}, deps = {}) {
           project_id: projectId,
           status: "KILLED",
           summary,
+          // Idempotency key for this transition. The backend persists
+          // `summary` only as a `taskStatusEvent` row, and it keys duplicate
+          // suppression off this id — without one it has to synthesize an id,
+          // which makes a redelivered report indistinguishable from a new
+          // event. Supplying it keeps failure reports both persisted AND
+          // deduplicated.
+          status_event_id: randomUUID(),
         },
       })
       .catch((err) => {
@@ -5005,8 +5741,14 @@ export function startDaemon(config = {}, deps = {}) {
   function reportCreateTaskFailure({ taskId, projectId, requestId, error, sendAck = true }) {
     const normalizedTaskId = taskId ? String(taskId) : "";
     const normalizedProjectId = projectId ? String(projectId) : "";
-    const message = error instanceof Error ? error.message : String(error);
-    logError(`Failed to create task ${normalizedTaskId || "unknown"}: ${message}`);
+    // Mirror reportRestartFailure: scrub before the message reaches the log
+    // AND the persisted status summary. An un-scrubbed create failure could
+    // carry the handoff URL or an inherited provider key.
+    const rawMessage = error instanceof Error ? error.message : String(error);
+    const message = redactSecretsForLogs(rawMessage, [AGENT_TOKEN]);
+    logError(
+      `[create-spawn] failure task=${normalizedTaskId || "unknown"}: ${message}`,
+    );
     if (sendAck) {
       sendAgentCommandAck({
         requestId,
@@ -5028,6 +5770,7 @@ export function startDaemon(config = {}, deps = {}) {
           project_id: normalizedProjectId,
           status: "KILLED",
           summary: message,
+          status_event_id: randomUUID(),
         },
       })
       .catch((err) => {
@@ -5272,15 +6015,13 @@ export function startDaemon(config = {}, deps = {}) {
 
       const env = {
         ...stripPtyTaskScopedEnv(process.env),
+        ...materializedConductorPathEnv,
         PWD: taskDir,
         CONDUCTOR_PROJECT_ID: projectId,
         CONDUCTOR_TASK_ID: taskId,
         CONDUCTOR_LAUNCHED_BY_DAEMON: "1",
         ...(cliCommand ? { CONDUCTOR_CLI_COMMAND: cliCommand } : {}),
       };
-      if (config.CONFIG_FILE) {
-        env.CONDUCTOR_CONFIG = config.CONFIG_FILE;
-      }
       if (AGENT_TOKEN) {
         env.CONDUCTOR_AGENT_TOKEN = AGENT_TOKEN;
       }
@@ -5288,7 +6029,10 @@ export function startDaemon(config = {}, deps = {}) {
         env.CONDUCTOR_BACKEND_URL = BACKEND_HTTP;
       }
 
-      const { child, tmuxSession } = spawnFireProcess({
+      // Sampled before the spawn so it is a true "everything after this is
+      // ours" watermark.
+      const logStartOffset = readLogSize(logPath);
+      const { child, tmuxSession, exitMarkerToken } = spawnFireProcess({
         taskId,
         args,
         env,
@@ -5346,10 +6090,25 @@ export function startDaemon(config = {}, deps = {}) {
       log(`New task workspace: ${taskDir}`);
       log(`Logs: ${logPath}`);
 
+      // Same diagnostics contract as the restart/fork path: without this a
+      // create_task whose backend dies at startup is a black box too.
+      const outputCapture = createChildOutputCapture({ logPath, logStartOffset });
+      const spawnedAtMs = Date.now();
+
       activeTaskProcesses.set(taskId, {
         child,
         projectId,
         logPath,
+        // Floor for later tail reads and the reaper's exit-marker scan: the
+        // log file is opened with flags "a" and survives in-place restarts,
+        // so bytes written before this run must not be attributed to it.
+        logStartOffset,
+        // Nonce this run's exit marker is tagged with, so the reaper only
+        // trusts a marker written by *this* wrapper shell.
+        exitMarkerToken,
+        // Consumed by the tmux liveness reaper as both a grace-period anchor
+        // and a lifetime figure for diagnostics.
+        spawnedAtMs,
         stopForceKillTimer: null,
         managedByFireBridge: true,
         tmuxSession: tmuxSession || null,
@@ -5383,13 +6142,20 @@ export function startDaemon(config = {}, deps = {}) {
         } else if (child.stderr && typeof child.stderr.on === "function" && logStream) {
           child.stderr.on("data", (chunk) => logStream.write(chunk));
         }
+        outputCapture.attach(child.stdout);
+        outputCapture.attach(child.stderr);
       } else if (child.stderr && typeof child.stderr.on === "function") {
+        outputCapture.attach(child.stderr);
         // Capture any error output emitted by the tmux client itself so
         // problems during session creation surface in daemon logs.
         child.stderr.on("data", (chunk) => {
           const text = chunk?.toString?.("utf8") ?? String(chunk ?? "");
           if (text.trim()) {
-            logError(`tmux(${tmuxSession}) stderr: ${text.trim()}`);
+            logError(
+              // Redact: this is the fire's raw stderr, which can carry the
+              // handoff share token (argv echo) and provider/agent keys.
+              `tmux(${tmuxSession}) stderr: ${redactSecretsForLogs(text.trim(), [AGENT_TOKEN])}`,
+            );
           }
         });
       }
@@ -5405,6 +6171,20 @@ export function startDaemon(config = {}, deps = {}) {
       child.on("exit", (code, signal) => {
         const active = activeTaskProcesses.get(taskId);
 
+        // This spawn was a tmux client but the record is gone: the reaper
+        // (or a stop) already retired this task and, in the reaper's case,
+        // already published its terminal status. Falling through would
+        // delete whatever record a restart has since installed and report a
+        // second, contradictory status — `shouldDaemonReportFireChildTerminal
+        // Status(undefined)` is true, so an `exit(0)` arriving late would
+        // announce COMPLETED over the reaper's verdict. Nothing left to do.
+        if (tmuxSession && !active) {
+          log(
+            `tmux client for task ${taskId} exited after its record was retired (code=${code}, signal=${signal || "null"}); nothing to report`,
+          );
+          return;
+        }
+
         // In tmux mode the `tmux new-session -d` client always exits
         // shortly after launching the Fire session. A clean exit (code 0,
         // no signal) just means the session was successfully created and
@@ -5468,6 +6248,18 @@ export function startDaemon(config = {}, deps = {}) {
             ? "completed"
             : `exited with code ${code}`;
 
+        const lifetimeMs = Date.now() - spawnedAtMs;
+        const outputTail = status === "KILLED" ? outputCapture.tail() : "";
+        if (status === "KILLED") {
+          logError(
+            `[create-spawn] abnormal exit task=${taskId} backend=${selectedBackend} ` +
+              `cwd=${taskDir} tmux=${tmuxSession || "none"} exit=${code ?? "null"} ` +
+              `signal=${signal || "null"} lifetime_ms=${lifetimeMs} log=${logPath} ` +
+              `output_tail=${outputTail ? JSON.stringify(outputTail) : "<empty>"}`,
+          );
+        }
+        const reportedSummary = outputTail ? `${summary}: ${outputTail}` : summary;
+
         if (!suppressExitStatusReport && shouldDaemonReportFireChildTerminalStatus(active)) {
           client
             .sendJson({
@@ -5476,7 +6268,8 @@ export function startDaemon(config = {}, deps = {}) {
                 task_id: taskId,
                 project_id: projectId,
                 status,
-                summary,
+                summary: reportedSummary,
+                status_event_id: randomUUID(),
               },
             })
             .catch((err) => {
@@ -5594,8 +6387,17 @@ export function startDaemon(config = {}, deps = {}) {
     // Probe the actual session and clean up stale entries on demand so
     // the restart gating below reflects reality, not the stale record.
     if (activeTarget?.tmuxMode && activeTarget.tmuxSession) {
-      const sessionAlive = await tmuxSessionExists(activeTarget.tmuxSession);
-      if (
+      // As in reclaim: only a conclusive answer may clear the record. This
+      // gate is what stops a double spawn, so trusting an inconclusive probe
+      // would start a second fire alongside a live one in the same worktree.
+      const { alive: sessionAlive, conclusive } = await probeTmuxSession(
+        activeTarget.tmuxSession,
+      );
+      if (!sessionAlive && !conclusive) {
+        logError(
+          `Could not determine whether tmux session ${activeTarget.tmuxSession} for task ${normalizedTargetTaskId} is alive; keeping the existing record before restart`,
+        );
+      } else if (
         !sessionAlive &&
         activeTaskProcesses.get(normalizedTargetTaskId) === activeTarget
       ) {
@@ -5915,6 +6717,7 @@ export function startDaemon(config = {}, deps = {}) {
 
     const env = {
       ...stripPtyTaskScopedEnv(process.env),
+      ...materializedConductorPathEnv,
       PWD: taskDir,
       CONDUCTOR_PROJECT_ID: normalizedProjectId,
       CONDUCTOR_TASK_ID: normalizedTargetTaskId,
@@ -5922,9 +6725,6 @@ export function startDaemon(config = {}, deps = {}) {
       ...(cliCommand ? { CONDUCTOR_CLI_COMMAND: cliCommand } : {}),
     };
     env.CONDUCTOR_RESUME_CWD = resolvedResumeCwd;
-    if (config.CONFIG_FILE) {
-      env.CONDUCTOR_CONFIG = config.CONFIG_FILE;
-    }
     if (AGENT_TOKEN) {
       env.CONDUCTOR_AGENT_TOKEN = AGENT_TOKEN;
     }
@@ -5932,13 +6732,38 @@ export function startDaemon(config = {}, deps = {}) {
       env.CONDUCTOR_BACKEND_URL = BACKEND_HTTP;
     }
 
-    const { child, tmuxSession } = spawnFireProcess({
+    // Two hazards below, one root cause: an in-place restart deliberately
+    // re-uses the previous run's working directory, so ANY artifact the last
+    // run left there can be mistaken for this run's own state. Both guards
+    // must run before the spawn.
+    //
+    // (1) The fire's durable upstream outbox lives in that directory. If the
+    // prior run was stopped while its websocket was down, its undelivered
+    // terminal `task_status_update` (KILLED/COMPLETED) is still on disk — and
+    // the run we are about to spawn would flush it during startup, marking the
+    // task killed seconds after resuming and then getting shot down by the
+    // server's `stop_task(task_already_killed)` reply. Purge those superseded
+    // events before the new fire can pick them up.
+    dropSupersededTerminalStatusEvents(taskDir, normalizedTargetTaskId);
+
+    // (2) The log file is opened with `flags:"a"` and re-used as well. Sample
+    // its size first so it is a true "everything after this is ours"
+    // watermark; without it the reaper reads the PREVIOUS run's exit marker.
+    const logStartOffset = readLogSize(logPath);
+
+    const { child, tmuxSession, exitMarkerToken } = spawnFireProcess({
       taskId: normalizedTargetTaskId,
       args,
       env,
       cwd: taskDir,
       logPath,
     });
+    // Bounded tail of the child's output + a spawn timestamp, so an abnormal
+    // exit can report *why* it died and how long it survived. `logPath` lets
+    // the capture recover the fire's own output in tmux mode, where the
+    // daemon's child is only the `tmux new-session` client.
+    const outputCapture = createChildOutputCapture({ logPath, logStartOffset });
+    const spawnedAtMs = Date.now();
 
     let logStream;
     try {
@@ -5969,6 +6794,11 @@ export function startDaemon(config = {}, deps = {}) {
       child,
       projectId: normalizedProjectId,
       logPath,
+      // See the create_task path: watermark for tail reads / exit-marker
+      // scans, the marker nonce, and the reaper's grace-period anchor.
+      logStartOffset,
+      exitMarkerToken,
+      spawnedAtMs,
       stopForceKillTimer: null,
       managedByFireBridge: true,
       tmuxSession: tmuxSession || null,
@@ -5990,17 +6820,32 @@ export function startDaemon(config = {}, deps = {}) {
       } else if (child.stderr && typeof child.stderr.on === "function" && logStream) {
         child.stderr.on("data", (chunk) => logStream.write(chunk));
       }
+      // Capture independently of logStream: when the log file cannot be
+      // opened (createWriteStream threw) the piping above is skipped
+      // entirely, which is exactly when we most need the tail.
+      outputCapture.attach(child.stdout);
+      outputCapture.attach(child.stderr);
     } else if (child.stderr && typeof child.stderr.on === "function") {
+      outputCapture.attach(child.stderr);
       child.stderr.on("data", (chunk) => {
         const text = chunk?.toString?.("utf8") ?? String(chunk ?? "");
         if (text.trim()) {
-          logError(`tmux(${tmuxSession}) stderr: ${text.trim()}`);
+          logError(
+              // Redact: this is the fire's raw stderr, which can carry the
+              // handoff share token (argv echo) and provider/agent keys.
+              `tmux(${tmuxSession}) stderr: ${redactSecretsForLogs(text.trim(), [AGENT_TOKEN])}`,
+            );
         }
       });
     }
 
     child.on("error", (err) => {
-      logError(`Failed to spawn restart CLI for ${normalizedTargetTaskId}: ${err.message}`);
+      logError(
+        `[fork-spawn] spawn error task=${normalizedTargetTaskId} mode=${normalizedMode} ` +
+          `backend=${selectedBackend} cwd=${taskDir} tmux=${tmuxSession || "none"}: ${
+            maskErrorForLogs(err)?.message || err
+          }`,
+      );
       if (logStream) {
         const ts = new Date().toLocaleString("sv-SE", { timeZone: "Asia/Shanghai" }).replace(" ", "T");
         logStream.write(`[daemon ${ts}] spawn error: ${err.message}\n`);
@@ -6010,6 +6855,16 @@ export function startDaemon(config = {}, deps = {}) {
     child.on("exit", (code, signal) => {
       const active = activeTaskProcesses.get(normalizedTargetTaskId);
 
+      // See the create path: a tmux client exiting after its record was
+      // retired must stay silent, or it would both clobber a replacement
+      // record and publish a status contradicting the reaper's verdict.
+      if (tmuxSession && !active) {
+        log(
+          `tmux client for restarted task ${normalizedTargetTaskId} exited after its record was retired (code=${code}, signal=${signal || "null"}); nothing to report`,
+        );
+        return;
+      }
+
       // In tmux mode the `tmux new-session -d` client always exits soon
       // after launching the session. A clean exit (code 0, no signal) means
       // Fire is now running detached under the tmux server — keep the task
@@ -6062,6 +6917,26 @@ export function startDaemon(config = {}, deps = {}) {
           ? "completed"
           : `exited with code ${code}`;
 
+      // Diagnostics for an abnormal exit. This is the line that makes a
+      // "branch task died instantly" incident debuggable: it names the mode,
+      // backend, cwd, tmux session, exit code/signal, how long the child
+      // survived, where its log is, and the tail of what it actually printed.
+      const lifetimeMs = Date.now() - spawnedAtMs;
+      const outputTail = outputCapture.tail();
+      if (status === "KILLED") {
+        logError(
+          `[fork-spawn] abnormal exit task=${normalizedTargetTaskId} mode=${normalizedMode} ` +
+            `backend=${selectedBackend} cwd=${taskDir} tmux=${tmuxSession || "none"} ` +
+            `exit=${code ?? "null"} signal=${signal || "null"} lifetime_ms=${lifetimeMs} ` +
+            `log=${logPath} output_tail=${outputTail ? JSON.stringify(outputTail) : "<empty>"}`,
+        );
+      }
+      // Surface the same tail in the status summary so it reaches the backend
+      // (task_status_events.summary) and the UI, instead of a bare
+      // "exited with code 1" that explains nothing.
+      const reportedSummary =
+        status === "KILLED" && outputTail ? `${summary}: ${outputTail}` : summary;
+
       const shouldReportTerminalStatus =
         !suppressExitStatusReport &&
         (!acceptedRestartAckSent || shouldDaemonReportFireChildTerminalStatus(active));
@@ -6076,7 +6951,9 @@ export function startDaemon(config = {}, deps = {}) {
               task_id: normalizedTargetTaskId,
               project_id: normalizedProjectId,
               status,
-              summary,
+              summary: reportedSummary,
+              // Idempotency key — see the note in reportRestartFailure.
+              status_event_id: randomUUID(),
             },
           })
           .catch((err) => {