fix(usage): make plan-usage chip work end-to-end + session-status footer

End-to-end testing on the real install surfaced several issues the unit
tests missed:

- Injection gate excluded real sessions: gated on workingDir under CASES_DIR,
  but sessions run in linked cases / real repos. Drop the gate (match
  updateCaseModel, which writes settings.local.json unconditionally).
- statusLine curl failed on HTTPS: prod is loopback HTTPS with a self-signed
  cert; `curl -s` returns 000. Use `curl -sk` (loopback only). applyStatusLineConfig
  now also updates an out-of-date ours-command so the fix propagates.
- Footer hijacked by limits: the in-terminal statusline now shows CURRENT
  SESSION status — `Opus 4.8 (1M context)  in:562,411 out:1,188  ctx:56%` —
  while the account-wide plan limits live only in the header chip.
- Chip blank after reload: persist last-known to localStorage and restore on
  load (account-global, slow-moving; 12h freshness guard).
- Readability + color: per-window green/yellow/red by usage (<60 / 60–84 / ≥85),
  bolder labels and values.
- Drop the renderIndexHtml strip (client-side reveal only, response-viewer
  pattern) — fixes server-index-title test fragility to local settings.

Footer fields flow through context_window.total_input_tokens/total_output_tokens
(schema + parser). Tests updated; verified live (footer, chip, colors, reload
persistence) on the real install.

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

src/hooks-config.ts

@@ -225,13 +225,17 @@ const STATUSLINE_MARKER = '/api/status-telemetry';
  * (present in every managed session via tmux setenv), so the config is static.
  */
 export function generateStatusLineCommand(): string {
+  // `curl -sk`: CODEMAN_API_URL is loopback HTTPS with a self-signed cert in the
+  // production setup; without -k curl returns 000 and the statusline shows
+  // nothing. -k is safe here (loopback only). Falls back to a brand string so the
+  // footer is never blank if Codeman is unreachable.
   return (
     `INPUT=$(cat 2>/dev/null || echo '{}'); ` +
     `printf '{"sessionId":"%s","data":%s}' "$CODEMAN_SESSION_ID" "$INPUT" | ` +
-    `curl -s -X POST "$CODEMAN_API_URL${STATUSLINE_MARKER}" ` +
+    `curl -sk -X POST "$CODEMAN_API_URL${STATUSLINE_MARKER}" ` +
     `-H 'Content-Type: application/json' ` +
     `-H "X-Codeman-Hook-Secret: $(cat "$CODEMAN_HOOK_SECRET_FILE" 2>/dev/null)" ` +
-    `--data @- 2>/dev/null || true`
+    `--data @- 2>/dev/null || echo codeman`
   );
 }
 
@@ -259,9 +263,10 @@ export async function applyStatusLineConfig(casePath: string, enabled: boolean):
   const isOurs = !!current && typeof current.command === 'string' && current.command.includes(STATUSLINE_MARKER);
 
   if (enabled) {
-    if (isOurs) return; // already configured — avoid rewriting on every session create
+    const desired = generateStatusLineCommand();
+    if (isOurs && current?.command === desired) return; // already current — skip rewrite
     if (!existsSync(claudeDir)) await mkdir(claudeDir, { recursive: true });
-    existing.statusLine = { type: 'command', command: generateStatusLineCommand() };
+    existing.statusLine = { type: 'command', command: desired }; // add, or update an out-of-date ours
   } else {
     if (!isOurs) return; // nothing of ours to remove (leave a user's own statusLine alone)
     delete existing.statusLine;

src/usage-telemetry.ts

@@ -46,7 +46,7 @@ export interface RawStatuslinePayload {
     five_hour?: { used_percentage?: number; resets_at?: number };
     seven_day?: { used_percentage?: number; resets_at?: number };
   };
-  context_window?: { used_percentage?: number };
+  context_window?: { used_percentage?: number; total_input_tokens?: number; total_output_tokens?: number };
   cost?: { total_cost_usd?: number };
   model?: { display_name?: string };
 }
@@ -88,13 +88,61 @@ export function parseStatusTelemetry(data: RawStatuslinePayload | undefined): St
   return t;
 }
 
-/** Compact in-terminal footer text (statusLine stdout / print-through). */
-export function formatStatusLineText(t: StatusTelemetry | null): string {
-  if (!t) return 'codeman';
-  const parts: string[] = [];
-  if (t.fiveHour) parts.push(`5h ${Math.round(t.fiveHour.usedPercentage)}%`);
-  if (t.sevenDay) parts.push(`7d ${Math.round(t.sevenDay.usedPercentage)}%`);
-  return parts.length ? `⟳ ${parts.join(' · ')}` : 'codeman';
+/**
+ * Current-session status for the in-terminal statusline footer. This is the
+ * "status of the current session" the user sees in Claude's footer — distinct
+ * from the account-wide plan limits, which live ONLY in the Codeman header chip.
+ */
+export interface SessionStatus {
+  modelDisplayName?: string;
+  inputTokens?: number;
+  outputTokens?: number;
+  contextUsedPercentage?: number;
+}
+
+/** Group a non-negative integer with thousands separators: 562411 → "562,411". */
+function withCommas(n: number): string {
+  return Math.max(0, Math.round(n))
+    .toString()
+    .replace(/\B(?=(\d{3})+(?!\d))/g, ',');
+}
+
+/** Extract current-session status (footer) from the raw payload. */
+export function parseSessionStatus(data: RawStatuslinePayload | undefined): SessionStatus | null {
+  if (!data) return null;
+  const s: SessionStatus = {};
+  if (typeof data.model?.display_name === 'string' && data.model.display_name) {
+    s.modelDisplayName = data.model.display_name.slice(0, 60);
+  }
+  const cw = data.context_window;
+  if (typeof cw?.total_input_tokens === 'number' && Number.isFinite(cw.total_input_tokens)) {
+    s.inputTokens = Math.max(0, cw.total_input_tokens);
+  }
+  if (typeof cw?.total_output_tokens === 'number' && Number.isFinite(cw.total_output_tokens)) {
+    s.outputTokens = Math.max(0, cw.total_output_tokens);
+  }
+  if (typeof cw?.used_percentage === 'number') {
+    s.contextUsedPercentage = clampPct(cw.used_percentage);
+  }
+  return Object.keys(s).length ? s : null;
+}
+
+/**
+ * Format the in-terminal statusline footer: the CURRENT SESSION's status —
+ * `Opus 4.8 (1M context)  in:562,411 out:1,188  ctx:56%` — NOT the plan limits,
+ * which live in the Codeman header chip. Claude requires a statusLine command to
+ * emit the rate_limits JSON at all, so this is what that command prints back.
+ */
+export function formatSessionStatusText(s: SessionStatus | null): string {
+  if (!s) return 'codeman';
+  const groups: string[] = [];
+  if (s.modelDisplayName) groups.push(s.modelDisplayName);
+  const tok: string[] = [];
+  if (s.inputTokens != null) tok.push(`in:${withCommas(s.inputTokens)}`);
+  if (s.outputTokens != null) tok.push(`out:${withCommas(s.outputTokens)}`);
+  if (tok.length) groups.push(tok.join(' '));
+  if (s.contextUsedPercentage != null) groups.push(`ctx:${Math.round(s.contextUsedPercentage)}%`);
+  return groups.length ? groups.join('  ') : 'codeman';
 }
 
 /**

src/web/public/app.js

@@ -581,6 +581,7 @@ class CodemanApp {
     const _kbSettings = this.loadAppSettingsFromStorage();
     if (_kbSettings.extendedKeyboardBar) KeyboardAccessoryBar.setMode('extended');
     this.applyHeaderVisibilitySettings();
+    this.restorePlanUsageChip();
     this.applySkin();
     this.applyTabWrapSettings();
     this.applyMonitorVisibility();
@@ -1818,6 +1819,24 @@ class CodemanApp {
   _onSessionStatusTelemetry(data) {
     this._latestPlanUsage = data;
     this.updatePlanUsageChip(data);
+    // Persist last-known so the chip shows immediately on the next page load /
+    // SSE reconnect, instead of staying blank until a session next renders.
+    try {
+      localStorage.setItem('codeman:planUsage', JSON.stringify({ t: Date.now(), data }));
+    } catch {}
+  }
+
+  // Repopulate the chip from the last-known value on page load (account-global,
+  // slow-moving; ignored if older than 12h). Live events refresh it.
+  restorePlanUsageChip() {
+    try {
+      const raw = localStorage.getItem('codeman:planUsage');
+      if (!raw) return;
+      const saved = JSON.parse(raw);
+      if (saved?.data && Date.now() - (saved.t || 0) < 12 * 3600 * 1000) {
+        this.updatePlanUsageChip(saved.data);
+      }
+    } catch {}
   }
 
   updatePlanUsageChip(data) {
@@ -1827,19 +1846,18 @@ class CodemanApp {
     const five = pct(data.fiveHour);
     const seven = pct(data.sevenDay);
     if (five === null && seven === null) return;
-    const parts = [];
-    if (five !== null) parts.push(`5h ${five}%`);
-    if (seven !== null) parts.push(`7d ${seven}%`);
-    chip.textContent = parts.join(' · ');
-    // Color hint as a window nears exhaustion.
-    const max = Math.max(five ?? 0, seven ?? 0);
-    chip.classList.toggle('header-plan-usage--warn', max >= 80 && max < 95);
-    chip.classList.toggle('header-plan-usage--crit', max >= 95);
+    // Per-window color by how much is used up: green < 60%, yellow 60–84%, red ≥ 85%.
+    const colorClass = (p) => (p >= 85 ? 'pu-red' : p >= 60 ? 'pu-yellow' : 'pu-green');
+    const seg = (label, p) =>
+      p === null
+        ? ''
+        : `<span class="pu-win"><span class="pu-label">${label}</span><span class="pu-val ${colorClass(p)}">${p}%</span></span>`;
+    chip.innerHTML = [seg('5h', five), seg('7d', seven)].filter(Boolean).join('<span class="pu-sep">·</span>');
     const resetStr = (w) => (w && w.resetAt ? new Date(w.resetAt).toLocaleString() : '—');
     chip.title =
       `Claude plan usage\n` +
-      `5-hour: ${five ?? '—'}% (resets ${resetStr(data.fiveHour)})\n` +
-      `Weekly: ${seven ?? '—'}% (resets ${resetStr(data.sevenDay)})`;
+      `5-hour limit: ${five ?? '—'}% used (resets ${resetStr(data.fiveHour)})\n` +
+      `Weekly limit: ${seven ?? '—'}% used (resets ${resetStr(data.sevenDay)})`;
   }
 
   // Scheduled runs

src/web/public/styles.css

@@ -8341,13 +8341,37 @@ kbd {
   white-space: nowrap;
   cursor: default;
 }
-.header-plan-usage--warn {
-  color: #e6b800;
-  border-color: rgba(230, 184, 0, 0.4);
+/* Readable two-window layout: dim uppercase label + bold, color-coded value. */
+.header-plan-usage .pu-win {
+  display: inline-flex;
+  align-items: baseline;
+  gap: 4px;
 }
-.header-plan-usage--crit {
-  color: var(--danger, #ff5c5c);
-  border-color: rgba(255, 92, 92, 0.5);
+.header-plan-usage .pu-label {
+  font-size: 0.66rem;
+  font-weight: 700;
+  color: var(--text);
+  opacity: 0.9;
+  text-transform: uppercase;
+  letter-spacing: 0.02em;
+}
+.header-plan-usage .pu-val {
+  font-weight: 700;
+}
+.header-plan-usage .pu-sep {
+  margin: 0 7px;
+  color: var(--text-dim);
+  opacity: 0.45;
+}
+/* Green/yellow/red by how much of the window is used up. */
+.header-plan-usage .pu-green {
+  color: #3fb950;
+}
+.header-plan-usage .pu-yellow {
+  color: #d6a01a;
+}
+.header-plan-usage .pu-red {
+  color: #f85149;
 }
 /* Marker class must out-specify the display:inline-flex !important above. */
 .header-plan-usage.header-plan-usage--hidden {

src/web/routes/session-routes.ts

@@ -298,10 +298,13 @@ export function registerSessionRoutes(
     }
 
     // Plan-usage statusLine exporter (App Settings → Display → "Plan Usage
-    // Limits"). Claude-only, and only inside Codeman-managed cases (never
-    // arbitrary user repos, which may carry a hand-authored statusLine). Adds or
-    // removes our exporter so toggling the setting off cleans up on next create.
-    if ((body.mode ?? 'claude') === 'claude' && workingDir.startsWith(CASES_DIR + '/')) {
+    // Limits"). Claude-only. Runs for ANY working dir — including linked cases /
+    // real repos, which is where most sessions actually run — mirroring
+    // updateCaseModel above (which likewise writes settings.local.json
+    // unconditionally). Safe against a user's own statusLine: applyStatusLineConfig
+    // only ever removes a statusLine that is OURS (marker-guarded), and adds/removes
+    // ours so toggling the setting off cleans up on the next create.
+    if ((body.mode ?? 'claude') === 'claude') {
       await applyStatusLineConfig(workingDir, body.statusLineTelemetry === true);
     }
 

src/web/routes/status-telemetry-routes.ts

@@ -17,7 +17,8 @@ import { StatusTelemetrySchema } from '../schemas.js';
 import { parseBody } from '../route-helpers.js';
 import {
   parseStatusTelemetry,
-  formatStatusLineText,
+  parseSessionStatus,
+  formatSessionStatusText,
   telemetrySignature,
   type RawStatuslinePayload,
 } from '../../usage-telemetry.js';
@@ -40,24 +41,28 @@ export function registerStatusTelemetryRoutes(app: FastifyInstance, ctx: Session
       return 'codeman';
     }
 
-    const telemetry = parseStatusTelemetry(data as RawStatuslinePayload | undefined);
-    if (!telemetry) {
-      // No plan-limit data yet (pre-first-response or non-subscriber auth).
-      return 'codeman';
-    }
+    const payload = data as RawStatuslinePayload | undefined;
 
-    const sig = telemetrySignature(telemetry);
-    if (lastSig.get(sessionId) !== sig) {
-      lastSig.set(sessionId, sig);
-      // Bound the map across long multi-session runs: prune dead sessions.
-      if (lastSig.size > 256) {
-        for (const id of [...lastSig.keys()]) {
-          if (!ctx.sessions.has(id)) lastSig.delete(id);
+    // Plan-usage limits (account-wide) → broadcast to the header chip, when
+    // present and changed (the statusline fires on every assistant message).
+    const telemetry = parseStatusTelemetry(payload);
+    if (telemetry) {
+      const sig = telemetrySignature(telemetry);
+      if (lastSig.get(sessionId) !== sig) {
+        lastSig.set(sessionId, sig);
+        // Bound the map across long multi-session runs: prune dead sessions.
+        if (lastSig.size > 256) {
+          for (const id of [...lastSig.keys()]) {
+            if (!ctx.sessions.has(id)) lastSig.delete(id);
+          }
         }
+        ctx.broadcast(SessionStatusTelemetry, { sessionId, ...telemetry });
       }
-      ctx.broadcast(SessionStatusTelemetry, { sessionId, ...telemetry });
     }
 
-    return formatStatusLineText(telemetry);
+    // In-terminal statusline footer → CURRENT SESSION status (model / tokens /
+    // context %), NOT the plan limits. Available from the first render, even
+    // before rate_limits appears.
+    return formatSessionStatusText(parseSessionStatus(payload));
   });
 }

src/web/schemas.ts

@@ -212,7 +212,13 @@ export const StatusTelemetrySchema = z.object({
           seven_day: RateLimitWindowSchema,
         })
         .optional(),
-      context_window: z.object({ used_percentage: z.number().optional() }).optional(),
+      context_window: z
+        .object({
+          used_percentage: z.number().optional(),
+          total_input_tokens: z.number().optional(),
+          total_output_tokens: z.number().optional(),
+        })
+        .optional(),
       cost: z.object({ total_cost_usd: z.number().optional() }).optional(),
       model: z.object({ display_name: z.string().max(100).optional() }).optional(),
     })

src/web/server.ts

@@ -1123,13 +1123,6 @@ export class WebServer extends EventEmitter {
     if (settings.showMultiMonitorButton === true) {
       html = html.replace(' btn-multimonitor--hidden', '');
     }
-    // Plan-usage chip: carries `header-plan-usage--hidden` by default (App
-    // Settings → Display → "Plan Usage Limits"); reveal by stripping the marker
-    // class when the user enabled it, so the chip paints in the right state on
-    // every normal reload (the client toggles the same class live on save).
-    if (settings.showPlanUsageLimits === true) {
-      html = html.replace(' header-plan-usage--hidden', '');
-    }
     // Detached single-session ("solo") window: inject the target session id so
     // the client can enter solo mode even if a (network-first) service worker
     // later serves a cached shell. The client primarily detects solo mode from