Persistent diagnostics + split resize verification + debug variant

[Suprhimp]

Summary

• Persistent file logging so error/crash logs survive app restart and can be shared from Settings (URLs/intent-extras/shell commands auto-redacted).
• Split LEFT pane resize fix via centralized viability gate, min-pane invariants (≥360 left, ≥320 right), and serialized resize-with-verification (re-reads dumpsys bounds, retries on mismatch).
• Debug install fix: applicationIdSuffix=".debug" so debug coexists with release; debug versionName/versionCode now auto-track the latest git tag (e.g. 1.4.0-debug) and commit count instead of the stale defaultConfig stub.

What changes

Diagnostics

• FileLogger — <filesDir>/logs/mirror.log (+ rotated .1), 512 KB × 2 cap, init-fail-safe degraded mode.
• DiagnosticSanitizer — redacts URLs (host only), --es key value extras, Executing: <shell> bodies; applied to every persisted write.
• CastlaApp installs a Thread.setDefaultUncaughtExceptionHandler that writes via FileLogger, then chains to the previous handler.
• MirrorDiagnostics.log() / endSession() now persist alongside Logcat.
• MirrorForegroundService.markTerminal(reason) (first-writer-wins via AtomicReference) at the 4 known silent-fail sites: VD_RECREATE_FAILED, SHIZUKU_REBIND_FAILED, PIPELINE_REBUILD_EXCEPTION, BROWSER_ACTIVATION_FAILED. performCleanup() is the sole owner of MirrorDiagnostics.endSession().
• Settings → new Diagnostic Logs section with Share / Copy Recent buttons; IO performed on Dispatchers.IO via rememberCoroutineScope.

Split resize

• New SplitMath (pure JVM): LEFT_PANE_MIN_PX=360, RIGHT_PANE_MIN_PX=320, MIN_TOTAL_PX=680, isSplitViable(), computeLeftPaneWidth().
• New ensureSplitViable(reason) gate; every split-entry path (launchSplitWebTarget, launchSplitExternalBrowserTarget, launchSplitStandardTarget, all 4 AppLaunchBus splitMode branches, relaunchPrimaryTaskForSplit) goes through it.
• splitTaskBounds() / primaryTaskBounds() now check(isSplitViable(...)) and call SplitMath directly — fail-fast instead of degenerate fallback.
• runResizeWithVerification: serialized via Mutex + per-pane Job cancel-previous, max 4 verify rounds, 800ms shell timeout, 16px tolerance, dumpsys-bounds parser (TaskBoundsParser) with graceful skip on OEM mismatch.

Build

• debug { applicationIdSuffix = ".debug" } → debug app is com.castla.mirror.debug, coexists with release.
• New gitLatestSemverTag() + gitCommitCount() helpers; androidComponents.onVariants(selector().withBuildType("debug")) overrides debug versionName / versionCode from git. CI release path is untouched (sed pattern only matches defaultConfig).
• Verified APK metadata: applicationId=com.castla.mirror.debug, versionName=1.4.0-debug, versionCode=97.

DUUL protocol

• Plan review: REVISE only on diagnosis-handoff heuristic; architectural analysis "production-ready as written".
• Code review (round 2): all logic-validation checks pass; remaining flags are heuristic (scope-punting on the pre-existing Robolectric-vs-SDK35 failures, diagnosis-handoff). The 6 Robolectric test-init failures exist on master too (verified by git stash + rerun on a clean checkout) and are unrelated to this PR.

Test plan

• ./gradlew :app:testDebugUnitTest — 277 of 283 pass; the 6 failures are pre-existing Robolectric ↔ compileSdk=35 infrastructure issues unrelated to this PR.
• New unit tests (33 total): DiagnosticSanitizerTest, FileLoggerTest, SplitMathTest, TaskBoundsParserTest — all green.
• ./gradlew :app:assembleDebug succeeds; APK metadata confirms split applicationId + git-tag-derived versionName.
• Manual: install debug build over an existing release install — should succeed without INSTALL_FAILED_VERSION_DOWNGRADE.
• Manual: trigger a mirror failure, open Settings → "Share Logs" → confirm mirror.log is attached and URLs are redacted.
• Manual: enter split mode several times — confirm left pane resizes consistently, no fullscreen-overlap regression.

Out of scope

• Identifying the actual Tesla mirror "loading screen → close" root cause; this PR adds the missing observability so a follow-up PR can diagnose from a real reproduction.
• Native crash / ANR capture.
• Robolectric upgrade for SDK 35 compatibility.

🤖 Generated with Claude Code

[vercel]

The latest updates on your projects. Learn more about Vercel for GitHub.

Project	Deployment	Actions	Updated (UTC)
website	Ready	Preview, Comment	Apr 27, 2026 3:01am