fix(audio): low-samplerate ogg encode + post-2.0 QA hygiene

Quality-VBR ogg (libvorbis -q:a) fixes 8 kHz 'encoder setup failed' in both ogg paths; drop empty COOKIE_SECRET ENV (app auto-generates); emit real bundle extractedSize; fix stale image-pad/compress-pdf QA specs.

apps/api/src/lib/media-tool.ts

@@ -94,7 +94,10 @@ const AUDIO_OUTPUTS: Record<string, AudioOutput> = {
   ".ogg": {
     ext: ".ogg",
     contentType: "audio/ogg",
-    encodeArgs: ["-c:a", "libvorbis", "-b:a", "192k"],
+    // Quality-based VBR, not a fixed bitrate: libvorbis fails with "encoder setup
+    // failed" when a high fixed bitrate (192k) is requested for a low sample rate
+    // (e.g. 8 kHz mono). -q:a 6 is ~192 kbps for normal audio and adapts to the rate.
+    encodeArgs: ["-c:a", "libvorbis", "-q:a", "6"],
   },
   ".opus": {
     ext: ".opus",

apps/api/src/routes/tools/convert-audio.ts

@@ -43,17 +43,13 @@ export function registerConvertAudio(app: FastifyInstance) {
             ];
           case "wav":
             return ["-i", inPath, "-vn", "-c:a", "pcm_s16le", out];
-          case "ogg":
-            return [
-              "-i",
-              inPath,
-              "-vn",
-              "-c:a",
-              "libvorbis",
-              "-b:a",
-              `${settings.bitrateKbps}k`,
-              out,
-            ];
+          case "ogg": {
+            // libvorbis ABR (-b:a) fails with "encoder setup failed" when the bitrate is
+            // too high for the source sample rate (e.g. 8 kHz). Use quality VBR (-q:a),
+            // which adapts to the rate. Map bitrate -> quality (~bitrate/32: 192k -> q6).
+            const quality = (settings.bitrateKbps / 32).toFixed(1);
+            return ["-i", inPath, "-vn", "-c:a", "libvorbis", "-q:a", quality, out];
+          }
           case "flac":
             return ["-i", inPath, "-vn", "-c:a", "flac", out];
           case "m4a":

docker/Dockerfile

@@ -373,8 +373,10 @@ ENV PORT=1349 \
     LOG_DIR=/data/logs \
     TRUST_PROXY=true \
     OIDC_ENABLED=false \
-    EXTERNAL_URL= \
-    COOKIE_SECRET=
+    EXTERNAL_URL=
+
+# COOKIE_SECRET is intentionally not baked in: the app auto-generates and persists one
+# on first boot if unset (see apps/api/src/index.ts). Override via runtime env to pin it.
 
 # NVIDIA Container Toolkit env vars (harmless on non-GPU systems)
 ENV NVIDIA_VISIBLE_DEVICES=all \

docker/build-bundle.sh

@@ -361,6 +361,15 @@ model_ids = [m["id"] for m in bundle.get("models", [])]
 
 py_ver = f"{sys.version_info.major}.{sys.version_info.minor}.{sys.version_info.micro}"
 
+# Uncompressed bundle size: BUILD_DIR holds site-packages + models at this point.
+# Surfaces the real extractedSize for docker/feature-manifest.json (used by the
+# disk-space pre-check in install_feature.py); several manifest entries were 0 before.
+extracted_size = sum(
+    os.path.getsize(os.path.join(root, name))
+    for root, _dirs, files in os.walk(os.environ["BUILD_DIR"])
+    for name in files
+)
+
 bundle_meta = {
     "bundleId": bundle_id,
     "version": manifest["imageVersion"],
@@ -368,6 +377,7 @@ bundle_meta = {
     "imageVersion": manifest["imageVersion"],
     "pythonVersion": py_ver,
     "models": model_ids,
+    "extractedSize": extracted_size,
 }
 
 out_path = os.path.join(os.environ["BUILD_DIR"], "bundle.json")

tests/integration/convert-audio.test.ts

@@ -49,7 +49,7 @@ describe.skipIf(!ffmpegAvailable())("convert-audio (requires ffmpeg)", () => {
   }, 60_000);
 
   it("converts mp3 to ogg and returns 200", async () => {
-    // Use mp3 fixture (44100 Hz) because libvorbis rejects the 8 kHz wav
+    // mp3 fixture (44100 Hz); the 8 kHz wav -> ogg case is the regression test below.
     const res = await runTool({ format: "ogg" }, MP3, "tiny.mp3");
     expect(res.statusCode).toBe(200);
     const envelope = JSON.parse(res.body);
@@ -63,4 +63,17 @@ describe.skipIf(!ffmpegAvailable())("convert-audio (requires ffmpeg)", () => {
     const outName = envelope.downloadUrl.split("/").pop() as string;
     expect(outName.endsWith(".ogg")).toBe(true);
   }, 60_000);
+
+  it("converts 8 kHz wav to ogg (regression: libvorbis low samplerate)", async () => {
+    // tiny.wav is 8 kHz; a fixed bitrate (-b:a) made libvorbis "encoder setup failed".
+    // The ogg path now uses -q:a (quality VBR), which adapts to the sample rate.
+    const res = await runTool({ format: "ogg" }, WAV, "tiny.wav");
+    expect(res.statusCode).toBe(200);
+    const envelope = JSON.parse(res.body);
+    expect(envelope.downloadUrl).toBeDefined();
+    const dl = await testApp.app.inject({ method: "GET", url: envelope.downloadUrl });
+    expect(dl.statusCode).toBe(200);
+    expect(dl.rawPayload.length).toBeGreaterThan(100);
+    expect((envelope.downloadUrl.split("/").pop() as string).endsWith(".ogg")).toBe(true);
+  }, 60_000);
 });

tests/qa/settings.qa.spec.ts

@@ -1035,7 +1035,7 @@ test.describe("IMAGE: image-pad", () => {
   test("target=1:1 -> output is square (max dim)", async ({ page }) => {
     const issues = instrument(page);
     await setupTool(page, "image-pad", IMG_200x150);
-    await selectOption(page, "image-pad-target", "1:1");
+    await clickButton(page, "1:1");
     const dl = await processAndDownload(page, "image-pad");
     if (!dl.ok) {
       bug({
@@ -1063,7 +1063,7 @@ test.describe("IMAGE: image-pad", () => {
   test("target=16:9 -> output is 16:9 ratio", async ({ page }) => {
     const issues = instrument(page);
     await setupTool(page, "image-pad", IMG_200x150);
-    await selectOption(page, "image-pad-target", "16:9");
+    await clickButton(page, "16:9");
     const dl = await processAndDownload(page, "image-pad");
     if (!dl.ok) {
       bug({
@@ -2027,16 +2027,22 @@ test.describe("DOCUMENT: extract-pages", () => {
 test.describe("DOCUMENT: compress-pdf", () => {
   test.setTimeout(TOOL_TIMEOUT * 2);
 
-  test("preset=screen -> output is valid PDF", async ({ page }) => {
+  // compress-pdf uses the shared CompressControls (quality / target-size modes),
+  // not screen/ebook/printer ghostscript presets. These drive the actual UI.
+  test("quality mode (q=20) -> output is valid PDF", async ({ page }) => {
     const issues = instrument(page);
     await setupTool(page, "compress-pdf", PDF_3PAGE);
-    await selectOption(page, "cpdf-preset", "screen");
+    await page
+      .getByRole("button", { name: /quality/i })
+      .first()
+      .click();
+    await setSlider(page, "compress-quality", 20);
     const dl = await processAndDownload(page, "compress-pdf", "long");
     if (!dl.ok) {
       bug({
         tool: "compress-pdf",
-        setting: "preset",
-        value: "screen",
+        setting: "quality",
+        value: "20",
         expected: "valid PDF",
         actual: dl.error ?? "error",
       });
@@ -2045,32 +2051,36 @@ test.describe("DOCUMENT: compress-pdf", () => {
     expect(magicMatches(dl.buf, "pdf")).toBe(true);
   });
 
-  test("preset=ebook -> output is valid PDF", async ({ page }) => {
+  test("quality mode (q=80) -> output is valid PDF", async ({ page }) => {
     const issues = instrument(page);
     await setupTool(page, "compress-pdf", PDF_3PAGE);
-    await selectOption(page, "cpdf-preset", "ebook");
+    await page
+      .getByRole("button", { name: /quality/i })
+      .first()
+      .click();
+    await setSlider(page, "compress-quality", 80);
     const dl = await processAndDownload(page, "compress-pdf", "long");
     if (!dl.ok)
       bug({
         tool: "compress-pdf",
-        setting: "preset",
-        value: "ebook",
+        setting: "quality",
+        value: "80",
         expected: "success",
         actual: dl.error ?? "error",
       });
     expect(dl.ok).toBe(true);
   });
 
-  test("preset=printer -> output is valid PDF", async ({ page }) => {
+  test("target-size mode -> output is valid PDF", async ({ page }) => {
     const issues = instrument(page);
     await setupTool(page, "compress-pdf", PDF_3PAGE);
-    await selectOption(page, "cpdf-preset", "printer");
+    await fillInput(page, "compress-target-size", 100);
     const dl = await processAndDownload(page, "compress-pdf", "long");
     if (!dl.ok)
       bug({
         tool: "compress-pdf",
-        setting: "preset",
-        value: "printer",
+        setting: "targetSize",
+        value: "100KB",
         expected: "success",
         actual: dl.error ?? "error",
       });