feat: Comms tab, MCP server upgrade, auth flow fix, build cleanup

- Add Comms dashboard tab (Fleet Comm + Chat) with 5 channels, SSE live updates
- Upgrade MCP server with port discovery, comms tools, ignition control
- Fix .exe launcher: frozen path resolution, _get_python() for supervisor start
- Auth flow: splash → profile select → dashboard (fleet starts idle until login)
- Add auto_start per-user preference (DB column + auth API + frontend wiring)
- Dashboard port fallback (5555 → 5556 → 5557) with .port discovery file
- Delete build.bat (replaced by cross-platform build.py)
- Roadmap: PT-5 build size optimization (PyQt6-WebEngine → Edge/WebView2)
- Gitignore: audit DBs, .port, baseline JSON files

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

Author: SwiftWing21

.gitignore

@@ -174,6 +174,15 @@ repo-descriptions.txt
 # ── Fleet — runtime state flags ──────────────────────────────────────────────
 fleet/.queue_paused
 fleet/.walkthrough_done
+fleet/.port
+
+# ── Audit databases / baselines (runtime, not source) ───────────────────────
+*.audit.db
+audit.db
+audit_baseline.json
+biged_audit.db
+biged_baseline.json
+.two-brain-audit.json
 
 # ── Fleet — learned packs (runtime RL output) ────────────────────────────────
 fleet/factorio/packs/learned/

BigEd/launcher/BigEdCC.spec

@@ -1,16 +1,12 @@
 # -*- mode: python ; coding: utf-8 -*-
 
-datas = [('brick.ico', '.'), ('icon_1024.png', '.'), ('modules', 'modules'), ('tray.py', '.'), ('launcher_webview.py', '.')]
-binaries = []
-hiddenimports = ['psutil', 'pynvml', 'webview', 'qtpy', 'PyQt6', 'PyQt6.QtWebEngineWidgets']
-
 
 a = Analysis(
     ['launcher.py'],
     pathex=[],
-    binaries=binaries,
-    datas=datas,
-    hiddenimports=hiddenimports,
+    binaries=[],
+    datas=[('brick.ico', '.'), ('icon_1024.png', '.'), ('modules', 'modules'), ('launcher_webview.py', '.'), ('tray.py', '.')],
+    hiddenimports=['psutil', 'pynvml', 'webview', 'qtpy', 'PyQt6', 'PyQt6.QtWebEngineWidgets'],
     hookspath=[],
     hooksconfig={},
     runtime_hooks=[],

BigEd/launcher/build.bat

@@ -55,9 +55,22 @@ def _build_splash_html() -> str:
 </body></html>"""
 
 SPLASH_HTML = _build_splash_html()
-FLEET_DIR = Path(__file__).resolve().parent.parent.parent / "fleet"
-DATA_DIR = Path(__file__).resolve().parent / "data"
-ICON_PATH = Path(__file__).resolve().parent / "icon_1024.png"
+
+# When frozen (PyInstaller --onefile), __file__ is inside a temp extraction dir.
+# Use the .exe's location as anchor instead.
+# Layout: BigEd/launcher/dist/BigEdCC.exe → project root is 3 levels up
+# Layout: BigEd/launcher/launcher_webview.py → project root is 3 levels up
+if getattr(sys, "frozen", False):
+    _EXE_DIR = Path(sys.executable).resolve().parent        # BigEd/launcher/dist/
+    _LAUNCHER_DIR = _EXE_DIR.parent                         # BigEd/launcher/
+    _PROJECT_ROOT = _LAUNCHER_DIR.parent.parent             # project root
+else:
+    _LAUNCHER_DIR = Path(__file__).resolve().parent         # BigEd/launcher/
+    _PROJECT_ROOT = _LAUNCHER_DIR.parent.parent             # project root
+
+FLEET_DIR = _PROJECT_ROOT / "fleet"
+DATA_DIR = _LAUNCHER_DIR / "data"
+ICON_PATH = _LAUNCHER_DIR / "icon_1024.png"
 
 _lock_sock: socket.socket | None = None
 _supervisor_proc: subprocess.Popen | None = None
@@ -145,17 +158,26 @@ def _relaunch_windowless():
 
 # -- Supervisor ----------------------------------------------------------------
 
+def _get_python() -> str:
+    """Return a real Python interpreter — sys.executable points to the .exe when frozen."""
+    if getattr(sys, "frozen", False):
+        import shutil
+        return shutil.which("python") or shutil.which("python3") or "python"
+    return sys.executable
+
+
 def _start_supervisor():
     global _supervisor_proc
     supervisor_py = str(FLEET_DIR / "supervisor.py")
+    python = _get_python()
     _supervisor_proc = subprocess.Popen(
-        [sys.executable, supervisor_py],
+        [python, supervisor_py],
         cwd=str(FLEET_DIR),
         stdout=subprocess.PIPE,
         stderr=subprocess.PIPE,
         creationflags=getattr(subprocess, "CREATE_NO_WINDOW", 0),
     )
-    log.info("Supervisor started (PID %s)", _supervisor_proc.pid)
+    log.info("Supervisor started (PID %s) via %s", _supervisor_proc.pid, python)
 
 
 def _stop_supervisor():
@@ -210,6 +232,17 @@ def status(self):
         except Exception:
             return {"healthy": False}
 
+    def open_file_dialog(self):
+        """Open native file dialog starting in user's home directory."""
+        if not _window:
+            return []
+        result = _window.create_file_dialog(
+            webview.OPEN_DIALOG,
+            directory=str(Path.home()),
+            allow_multiple=True,
+        )
+        return list(result) if result else []
+
     def quit(self):
         _shutdown()
 
@@ -477,6 +510,9 @@ def main():
 
     _load_secrets_to_env()
 
+    # Sweep orphan fleet processes from prior sessions before anything else
+    _sweep_zombies()
+
     if not _acquire_instance_lock():
         log.info("Another instance is already running (port %s held)", LOCK_PORT)
         try:
@@ -504,25 +540,11 @@ def main():
 
     _relaunch_windowless()
 
-    # Check auto_start setting — if false, pause queue so fleet opens idle
-    _auto_start = True
-    try:
-        toml_path = FLEET_DIR / "fleet.toml"
-        if toml_path.exists():
-            try:
-                import tomllib
-            except ImportError:
-                import tomli as tomllib
-            cfg = tomllib.loads(toml_path.read_text(encoding="utf-8"))
-            _auto_start = cfg.get("fleet", {}).get("auto_start", True)
-    except Exception:
-        pass
-
-    if not _auto_start:
-        # Create pause file so workers don't process tasks on boot
-        pause_file = FLEET_DIR / ".queue_paused"
-        pause_file.write_text("paused_by_launcher", encoding="utf-8")
-        log.info("auto_start=false — fleet will open idle (queue paused)")
+    # Always start fleet idle — user profile's auto_start preference
+    # is checked after login in the dashboard frontend
+    pause_file = FLEET_DIR / ".queue_paused"
+    pause_file.write_text("paused_by_launcher", encoding="utf-8")
+    log.info("Fleet will open idle (queue paused until after login)")
 
     # Show splash window immediately — no waiting
     _window = webview.create_window(

BigEd/launcher/launcher_webview.py

@@ -1555,6 +1555,28 @@ Completed 2026-03-18. Linux AppImage (`package_linux.py`), macOS .app/DMG (`pack
 
 Completed 2026-03-18. GitHub Actions CI matrix (Win/Linux/macOS x Python 3.11/3.12), smoke test per platform, skill import verification, CLI command verification.
 
+#### PT-5: Build Size Optimization
+- **Goal:** Reduce BigEdCC.exe from 261MB (PyQt6-WebEngine bloat) to < 80MB
+- **Grading Alignment:** Performance → impact: +1 pt / weight: 10%; Usability → faster downloads
+- **Dependencies:** None (independent of feature work)
+- **Est. Tokens:** ~8k (M)
+- **Status:** [ ] Not started
+
+**Phase 1: Drop QtWebEngine** (biggest win — ~180MB of the 261MB)
+- [ ] Switch pywebview to Edge/WebView2 backend on Windows (`PYWEBVIEW_GUI=edgechromium`) — ships with Windows 10+, zero bundle cost
+- [ ] Remove PyQt6-WebEngine from requirements.txt (keep PyQt6 if needed for non-web UI, or drop entirely)
+- [ ] Fallback chain: edgechromium → qt → cef (build.py sets env var)
+
+**Phase 2: PyInstaller trimming** (~additional 20-30MB reduction)
+- [ ] `--exclude-module` for unused stdlib (tkinter, test, unittest, lib2to3)
+- [ ] Split `requirements.txt` — anthropic/google-genai are fleet-level, not needed in launcher .exe
+- [ ] UPX compression on final binary (typically 30-40% reduction)
+
+**Phase 3: GitHub Releases distribution**
+- [ ] GitHub Actions workflow: on tag push, `build.py --production`, upload artifacts to GitHub Release
+- [ ] Launcher auto-update checks GitHub Releases API for latest version
+- [ ] README download badges pointing to latest release
+
 ### CT — Cost Intelligence (Token Usage & Optimization)
 
 #### CT-1: Usage Capture [DONE]