Train 1D: merge via --admin on .113 validation

Squash merge from local merge-train (Hard Rule owner-approved). Tip 029cdf4215cf465f0e1716ac9f84a84692b1e881 validated on 192.168.0.113: 26631/26653 pass.

open-sse/services/contextManager.ts

@@ -305,7 +305,11 @@ export function compressContext(
   const targetTokens = Math.max(0, maxTokens - reserveTokens);
 
   let messages = [...body.messages];
-  let currentTokens = estimateTokens(JSON.stringify(messages));
+  // #8594: pass the structured messages array directly — estimateTokens walks it for
+  // inline base64 image blocks (#8368) and substitutes a bounded per-image estimate.
+  // JSON.stringify()-ing first forces the char/4 text path and mis-measures a ~500KB
+  // image as ~125k tokens, triggering needless compression / context loss.
+  let currentTokens = estimateTokens(messages);
   const stats = { original: currentTokens, layers: [] as { name: string; tokens: number }[] };
 
   // Already fits
@@ -315,7 +319,7 @@ export function compressContext(
 
   // Layer 1: Trim tool_result/tool messages
   messages = trimToolMessages(messages, 2000); // Max 2000 chars per tool result
-  currentTokens = estimateTokens(JSON.stringify(messages));
+  currentTokens = estimateTokens(messages); // #8594: object-path keeps the #8368 image estimate
   stats.layers.push({ name: "trim_tools", tokens: currentTokens });
 
   if (currentTokens <= targetTokens) {
@@ -328,7 +332,7 @@ export function compressContext(
 
   // Layer 2: Compress structured thinking blocks (remove from non-last assistant messages)
   messages = compressThinking(messages);
-  currentTokens = estimateTokens(JSON.stringify(messages));
+  currentTokens = estimateTokens(messages); // #8594: object-path keeps the #8368 image estimate
   stats.layers.push({ name: "compress_thinking", tokens: currentTokens });
 
   if (currentTokens <= targetTokens) {
@@ -341,7 +345,7 @@ export function compressContext(
 
   // Layer 3: Aggressive purification — drop oldest messages keeping system + last N pairs
   messages = purifyHistory(messages, targetTokens);
-  currentTokens = estimateTokens(JSON.stringify(messages));
+  currentTokens = estimateTokens(messages); // #8594: object-path keeps the #8368 image estimate
   stats.layers.push({ name: "purify_history", tokens: currentTokens });
 
   return {
@@ -427,7 +431,9 @@ function purifyHistory(messages: Record<string, unknown>[], targetTokens: number
     // orphan tool_results that Claude rejects ("tool_result without preceding tool_use").
     candidate = fixToolPairs(candidate);
     candidate = stripTrailingAssistantOrphanToolUse(candidate);
-    const tokens = estimateTokens(JSON.stringify(candidate));
+    // #8594: measure the candidate structure directly so image-bearing turns are not
+    // over-counted and pruned during the binary search.
+    const tokens = estimateTokens(candidate);
     if (tokens <= targetTokens) break;
     keep = Math.max(2, Math.floor(keep * 0.7)); // Drop 30% each iteration
   }

tests/unit/8594-compress-image-token-stringify.test.ts

@@ -0,0 +1,94 @@
+import test from "node:test";
+import assert from "node:assert/strict";
+import { compressContext } from "../../open-sse/services/contextManager.ts";
+
+// #8594 — six production call sites (compressContext layers + purifyHistory binary
+// search + the combo.ts fallback threshold) pre-JSON.stringify the messages before
+// handing them to estimateTokens(). Stringifying forces the char/4 text path and
+// undoes the #8368 inline-base64-image bounded estimate, so an image-bearing request
+// that fits comfortably is mis-measured as ~100× larger and compressed needlessly.
+
+function makeFakePngBase64(approxBytes: number): string {
+  return Buffer.alloc(approxBytes, 65).toString("base64");
+}
+
+test("#8594: compressContext does NOT compress a within-limit inline-image request", () => {
+  // ~500KB image => ~666KB base64. As raw text that is ~166k tokens (over the limit);
+  // as a bounded image estimate it is ~1.2k tokens (well under). maxTokens=20000 sits
+  // between the two, so the bug (stringify) trips compression and the fix does not.
+  const base64 = makeFakePngBase64(500_000);
+  const body = {
+    model: "gpt-image-vision",
+    messages: [
+      { role: "system", content: "You are a helpful vision assistant." },
+      {
+        role: "user",
+        content: [
+          { type: "text", text: "What is in this image?" },
+          { type: "image_url", image_url: { url: `data:image/png;base64,${base64}` } },
+        ],
+      },
+    ],
+  };
+
+  const result = compressContext(body, { maxTokens: 20000, reserveTokens: 0 });
+
+  assert.equal(
+    result.compressed,
+    false,
+    `BUG #8594 reproduced: within-limit image request was compressed. ` +
+      `stats.original=${(result.stats as { original?: number }).original} tokens ` +
+      `(should be a bounded ~1.2k image estimate, not the ~166k base64-as-text value)`
+  );
+  assert.ok(
+    (result.stats as { original: number }).original < 5000,
+    `expected bounded image-token estimate (<5000), got ${(result.stats as { original: number }).original}`
+  );
+});
+
+test("#8594: purifyHistory keeps all image-bearing turns when they fit within the limit", () => {
+  // Multiple image messages that, measured correctly, fit under the limit. The bug
+  // makes the Layer-3 binary search over-estimate and prune turns; the fix preserves them.
+  const base64 = makeFakePngBase64(200_000);
+  const imageTurn = (n: number) => ({
+    role: "user",
+    content: [
+      { type: "text", text: `Image number ${n}` },
+      { type: "image_url", image_url: { url: `data:image/png;base64,${base64}` } },
+    ],
+  });
+  const body = {
+    model: "gpt-image-vision",
+    messages: [
+      { role: "system", content: "vision" },
+      imageTurn(1),
+      { role: "assistant", content: "ok 1" },
+      imageTurn(2),
+      { role: "assistant", content: "ok 2" },
+      imageTurn(3),
+      { role: "assistant", content: "ok 3" },
+    ],
+  };
+  const originalCount = body.messages.length;
+
+  const result = compressContext(body, { maxTokens: 20000, reserveTokens: 0 });
+
+  assert.equal(result.compressed, false, "within-limit image history must not be compressed");
+  assert.equal(
+    (result.body as { messages: unknown[] }).messages.length,
+    originalCount,
+    "all image-bearing turns must be retained when they fit"
+  );
+});
+
+test("#8594: control — an oversized text request is still compressed (no regression)", () => {
+  const body = {
+    model: "gpt-text",
+    messages: [
+      { role: "system", content: "s" },
+      { role: "user", content: "a".repeat(200_000) }, // ~50k tokens, over a 20k limit
+    ],
+  };
+  const result = compressContext(body, { maxTokens: 20000, reserveTokens: 0 });
+  assert.equal(result.compressed, true, "oversized text must still trigger compression");
+});