fix: use TERMINAL_TAIL_SIZE constant and add client-drop recovery

Two hardcoded `256 * 1024` tail sizes in app.js bypassed the
TERMINAL_TAIL_SIZE constant (128KB), causing stale cached browsers
to fetch 256KB buffers even after the constant was reduced to prevent
WebGL GPU stalls. Also adds a self-recovery timer that reloads the
terminal buffer after client-side data drops, preventing permanent
display corruption.

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

CLAUDE.md

@@ -80,7 +80,7 @@ Codeman is a Claude Code session manager with web interface and autonomous Ralph
 
 **CI**: `.github/workflows/ci.yml` runs `typecheck`, `lint`, `format:check` on push to master (Node 22). Tests excluded (they spawn tmux).
 
-**Code style**: Prettier (`singleQuote: true`, `printWidth: 120`, `trailingComma: "es5"`). ESLint allows `no-console`, warns on `@typescript-eslint/no-explicit-any`. Does not lint `app.js` or `scripts/**/*.mjs`.
+**Code style**: Prettier (`singleQuote: true`, `printWidth: 120`, `trailingComma: "es5"`). ESLint flat config (`eslint.config.js`) allows `no-console`, warns on `@typescript-eslint/no-explicit-any`. Ignores: `app.js`, `scripts/**/*.mjs`, `src/web/public/vendor/**`, `tools/**`, `remotion/**`.
 
 ## Common Gotchas
 
@@ -108,9 +108,9 @@ Codeman is a Claude Code session manager with web interface and autonomous Ralph
 | **State** | `src/state-store.ts`, `src/run-summary.ts`, `src/session-lifecycle-log.ts` | |
 | **Infra** | `src/hooks-config.ts`, `src/push-store.ts`, `src/tunnel-manager.ts`, `src/image-watcher.ts`, `src/file-stream-manager.ts` | |
 | **Plan** | `src/plan-orchestrator.ts`, `src/prompts/*.ts`, `src/templates/claude-md.ts` | |
-| **Web** | `src/web/server.ts`, `src/web/sse-events.ts`, `src/web/routes/*.ts` (13 modules), `src/web/ports/*.ts`, `src/web/middleware/auth.ts`, `src/web/schemas.ts` | |
+| **Web** | `src/web/server.ts`, `src/web/sse-events.ts`, `src/web/routes/*.ts` (12 route modules + barrel), `src/web/ports/*.ts`, `src/web/middleware/auth.ts`, `src/web/schemas.ts` | |
 | **Frontend** | `src/web/public/app.js` ★ (~11.8K lines) + 10 JS modules (incl. `sw.js` service worker) | |
-| **Types** | `src/types/index.ts` → 14 domain files | See `@fileoverview` in index.ts |
+| **Types** | `src/types/index.ts` → 13 domain files | See `@fileoverview` in index.ts |
 
 ★ = Large file (>50KB). All files have `@fileoverview` JSDoc — read that before diving in.
 
@@ -170,7 +170,7 @@ Frontend JS modules have `@fileoverview` with `@dependency`/`@loadorder` tags. L
 
 ### API Routes
 
-~111 handlers across 13 route files in `src/web/routes/`: system (35), sessions (24), ralph (9), plan (8), respawn (7), cases (7), files (5), mux (5), scheduled (4), push (4), teams (2), hooks (1). Each file has `@fileoverview` with endpoint details.
+~111 handlers across 12 route files in `src/web/routes/`: system (35), sessions (24), ralph (9), plan (8), respawn (7), cases (7), files (5), mux (5), scheduled (4), push (4), teams (2), hooks (1). Each file has `@fileoverview` with endpoint details.
 
 ## Adding Features
 
@@ -179,7 +179,7 @@ Frontend JS modules have `@fileoverview` with `@dependency`/`@loadorder` tags. L
 - **Session setting**: Add to `SessionState`, include in `session.toState()`, call `persistSessionState()`
 - **Hook event**: Add to `HookEventType`, add hook in `hooks-config.ts:generateHooksConfig()`, update `HookEventSchema`
 - **Mobile feature**: Add to relevant singleton, guard with `MobileDetection.isMobile()`
-- **New test**: Pick unique port (search `const PORT =`). Integration: ports 3099-3211. Route tests: `app.inject()` — see `test/routes/_route-test-utils.ts`.
+- **New test**: Pick unique port (search `const PORT =`). Route tests use `app.inject()` (no port needed) — see `test/routes/_route-test-utils.ts`.
 
 **Validation**: Zod v4 (different API from v3). Define schemas in `schemas.ts`, use `.parse()`/`.safeParse()`.
 
@@ -238,7 +238,6 @@ Key: `scripts/tmux-manager.sh` (safe tmux mgmt), `scripts/tunnel.sh` (tunnel sta
 ## Common Workflows
 
 **Bug investigation**: Dev server → reproduce in browser → check terminal + `~/.codeman/state.json`.
-**API endpoint**: Types in `src/types/*.ts` → route in `src/web/routes/*-routes.ts` → SSE event if needed → handle in `app.js`.
 **Respawn changes**: Read `docs/respawn-state-machine.md` first. Use `MockSession` from `test/respawn-test-utils.ts`.
 
 ## Tunnel

src/web/public/app.js

@@ -1817,14 +1817,24 @@ class CodemanApp {
     if (data.id === this.activeSessionId) {
       if (data.data.length > 32768) _crashDiag.log(`TERMINAL: ${(data.data.length/1024).toFixed(0)}KB`);
 
-      // Hard cap: track total bytes queued across ALL buffers (pendingWrites +
-      // flickerFilterBuffer + loadBufferQueue). When rAF is throttled (tab
+      // Hard cap: track total bytes queued in render buffers (pendingWrites +
+      // flickerFilterBuffer). When rAF is throttled (tab
       // backgrounded, GPU busy), data accumulates with no flush, reaching
-      // 889KB+ and freezing Chrome for minutes. Drop data beyond 96KB —
-      // the server sends session:needsRefresh to recover.
+      // 889KB+ and freezing Chrome for minutes. Drop data beyond 128KB and
+      // schedule a buffer reload to recover the display once the burst subsides.
       const queued = (this.pendingWrites?.reduce((s, w) => s + w.length, 0) || 0)
         + (this.flickerFilterBuffer?.length || 0);
-      if (queued > 131072) return; // 128KB — drop to prevent accumulation
+      if (queued > 131072) { // 128KB — drop to prevent accumulation
+        // Schedule a self-recovery: reload the full terminal buffer once the
+        // queue drains (debounced to avoid hammering the API during sustained bursts).
+        if (!this._clientDropRecoveryTimer) {
+          this._clientDropRecoveryTimer = setTimeout(() => {
+            this._clientDropRecoveryTimer = null;
+            this._onSessionNeedsRefresh();
+          }, 2000);
+        }
+        return;
+      }
 
       this.batchTerminalWrite(data.data);
     }
@@ -1835,8 +1845,7 @@ class CodemanApp {
     // so reload the buffer to recover from any display corruption.
     if (!this.activeSessionId || !this.terminal) return;
     try {
-      const tailSize = 256 * 1024;
-      const res = await fetch(`/api/sessions/${this.activeSessionId}/terminal?tail=${tailSize}`);
+      const res = await fetch(`/api/sessions/${this.activeSessionId}/terminal?tail=${TERMINAL_TAIL_SIZE}`);
       const data = await res.json();
       if (data.terminalBuffer) {
         this.terminal.clear();
@@ -3532,6 +3541,7 @@ class CodemanApp {
     this._tabCompletionRetries = 0;
     this._tabCompletionBaseText = null;
     if (this._tabCompletionFallback) { clearTimeout(this._tabCompletionFallback); this._tabCompletionFallback = null; }
+    if (this._clientDropRecoveryTimer) { clearTimeout(this._clientDropRecoveryTimer); this._clientDropRecoveryTimer = null; }
 
     // Clean up pending terminal writes to prevent old session data from appearing in new session
     if (this.syncWaitTimeout) {
@@ -3634,7 +3644,7 @@ class CodemanApp {
 
     // Load terminal buffer for this session
     // Show cached content instantly while fetching fresh data in background.
-    // Use tail mode for faster initial load (256KB is enough for recent visible content).
+    // Use tail mode for faster initial load (128KB is enough for recent visible content).
     //
     // Protect flushed state during buffer load: terminal.write() can trigger
     // xterm.js onData responses (DA, OSC, etc.) that would otherwise clear
@@ -3664,8 +3674,7 @@ class CodemanApp {
       }
 
       _crashDiag.log('FETCH_START');
-      const tailSize = 256 * 1024;
-      const res = await fetch(`/api/sessions/${sessionId}/terminal?tail=${tailSize}`);
+      const res = await fetch(`/api/sessions/${sessionId}/terminal?tail=${TERMINAL_TAIL_SIZE}`);
       if (selectGen !== this._selectGeneration) { if (this._isLoadingBuffer) this._finishBufferLoad(); this._restoringFlushedState = false; return; }
       const data = await res.json();
       _crashDiag.log(`FETCH_DONE: ${data.terminalBuffer ? (data.terminalBuffer.length/1024).toFixed(0) + 'KB' : 'empty'} truncated=${data.truncated}`);