fix(flush_memories): always deduct headroom + resolve flush aux model + trim defence

Three fixes for flush_memories / compression context window overflow:

1. ALWAYS deduct headroom before comparing aux_context vs threshold.
   #15631 only deducted inside 'if aux_context < threshold' — which
   never fires in the common same-model case (threshold = context × 0.50
   means aux_context > threshold always). Now headroom is computed
   unconditionally and effective_limit = aux_context - headroom is
   compared against threshold.

2. Also resolve flush_memories auxiliary model in the feasibility check.
   If the user configures separate auxiliary.flush_memories provider,
   the flush model's smaller context was unchecked.

3. Defence-in-depth trimming in flush_memories() for CLI /new and
   gateway resets that bypass preflight compression entirely.

run_agent.py

@@ -2402,6 +2402,34 @@ class AIAgent:
                 provider=getattr(self, "provider", ""),
             )
 
+            # Also resolve the flush_memories auxiliary model — it may differ
+            # from the compression model when the user configures separate
+            # auxiliary.flush_memories.provider/model, or when the fallback
+            # chain lands on a different provider.  flush_memories runs with
+            # the FULL pre-compression conversation, so its model's context
+            # must also be respected.
+            try:
+                flush_client, flush_model = get_text_auxiliary_client(
+                    "flush_memories",
+                    main_runtime=self._current_main_runtime(),
+                )
+                if flush_client and flush_model:
+                    _flush_ctx = get_model_context_length(
+                        flush_model,
+                        base_url=str(getattr(flush_client, "base_url", "") or ""),
+                        api_key=str(getattr(flush_client, "api_key", "") or ""),
+                        provider=getattr(self, "provider", ""),
+                    )
+                    if _flush_ctx and _flush_ctx < aux_context:
+                        logger.info(
+                            "flush_memories model %s context (%d) < compression "
+                            "model %s context (%d) — using the smaller value",
+                            flush_model, _flush_ctx, aux_model, aux_context,
+                        )
+                        aux_context = _flush_ctx
+            except Exception:
+                pass  # Non-fatal — fall through with compression model's context
+
             # Hard floor: the auxiliary compression model must have at least
             # MINIMUM_CONTEXT_LENGTH (64K) tokens of context.  The main model
             # is already required to meet this floor (checked earlier in
@@ -2421,29 +2449,25 @@ class AIAgent:
                 )
 
             threshold = self.context_compressor.threshold_tokens
-            if aux_context < threshold:
-                # Auto-correct: lower the live session threshold so
-                # compression actually works this session.  The hard floor
-                # above guarantees aux_context >= MINIMUM_CONTEXT_LENGTH,
-                # so the new threshold is always >= 64K.
-                #
-                # Headroom: the threshold budgets RAW MESSAGES only, but the
-                # actual request auxiliary callers send also includes the
-                # system prompt and every tool schema.  With 50+ tools that
-                # overhead can be 25-30K tokens; setting new_threshold =
-                # aux_context directly would let messages grow right to the
-                # aux limit and the first compression/flush request would
-                # overflow with HTTP 400.  Subtract a dynamic headroom
-                # estimate so the full request still fits.
-                from agent.model_metadata import estimate_request_tokens_rough
-                tool_overhead = estimate_request_tokens_rough([], tools=self.tools)
-                # System prompt is not yet built at __init__ time; allow a
-                # conservative 10K budget (SOUL/AGENTS.md + memory snapshot +
-                # skills guidance) plus 2K for the flush instruction and a
-                # small safety margin.
-                headroom = tool_overhead + 12_000
+
+            # Headroom: the threshold budgets RAW MESSAGES only, but the
+            # actual request auxiliary callers (compression summariser and
+            # flush_memories) send also includes the system prompt and every
+            # tool schema.  We must ensure threshold + headroom <= aux_context
+            # or the first compression/flush request will overflow.
+            #
+            # This applies even when aux_context > threshold (the common
+            # same-model case after a155b4a1) — e.g. 128K context, 85%
+            # threshold = 108K, 20K overhead → 108K + 20K = 128K exactly
+            # at the limit, and any token-estimate variance causes a 400.
+            from agent.model_metadata import estimate_request_tokens_rough
+            tool_overhead = estimate_request_tokens_rough([], tools=self.tools)
+            headroom = tool_overhead + 12_000
+            effective_limit = max(aux_context - headroom, MINIMUM_CONTEXT_LENGTH)
+
+            if effective_limit < threshold:
                 old_threshold = threshold
-                new_threshold = max(aux_context - headroom, MINIMUM_CONTEXT_LENGTH)
+                new_threshold = effective_limit
                 self.context_compressor.threshold_tokens = new_threshold
                 # Keep threshold_percent in sync so future main-model
                 # context_length changes (update_model) re-derive from a
@@ -7992,6 +8016,67 @@ class AIAgent:
                 messages.pop()  # remove flush msg
                 return
 
+            # ── Defence-in-depth: trim messages to fit auxiliary context ──
+            #
+            # _check_compression_model_feasibility already lowers the
+            # compression threshold so conversations *triggered by preflight
+            # compression* should fit.  But flush_memories is also called
+            # from CLI /new and gateway session resets — paths that bypass
+            # the preflight check entirely.  Trim here as a safety net.
+            try:
+                from agent.auxiliary_client import get_text_auxiliary_client
+                from agent.model_metadata import (
+                    get_model_context_length,
+                    estimate_messages_tokens_rough,
+                )
+                _fc, _fm = get_text_auxiliary_client(
+                    "flush_memories",
+                    main_runtime=self._current_main_runtime(),
+                )
+                _fctx = 0
+                if _fc and _fm:
+                    _fctx = get_model_context_length(
+                        _fm,
+                        base_url=str(getattr(_fc, "base_url", "") or ""),
+                        api_key=str(getattr(_fc, "api_key", "") or ""),
+                        provider=getattr(self, "provider", ""),
+                    )
+                if not _fctx:
+                    _fctx = getattr(
+                        getattr(self, "context_compressor", None),
+                        "context_length", 0,
+                    )
+                if _fctx:
+                    _budget = _fctx - 5120 - 500  # output + tool schema
+                    if _budget > 0:
+                        _est = estimate_messages_tokens_rough(api_messages)
+                        if _est > _budget:
+                            _sys = []
+                            _conv = api_messages
+                            if api_messages and api_messages[0].get("role") == "system":
+                                _sys = [api_messages[0]]
+                                _conv = api_messages[1:]
+                            _rem = _budget - estimate_messages_tokens_rough(_sys)
+                            _kept: list = []
+                            _acc = 0
+                            for _m in reversed(_conv):
+                                _mt = estimate_messages_tokens_rough([_m])
+                                if _acc + _mt > _rem:
+                                    break
+                                _kept.append(_m)
+                                _acc += _mt
+                            _kept.reverse()
+                            if len(_kept) < 3 and len(_conv) >= 3:
+                                _kept = _conv[-3:]
+                            api_messages = _sys + _kept
+                            logger.info(
+                                "flush_memories: trimmed %d→%d msgs to fit "
+                                "%d-token aux context",
+                                len(_sys) + len(_conv), len(api_messages), _fctx,
+                            )
+            except Exception as _te:
+                logger.debug("flush_memories: context trim failed: %s", _te)
+
             # Use auxiliary client for the flush call when available --
             # it's cheaper and avoids Codex Responses API incompatibility.
             from agent.auxiliary_client import (

tests/run_agent/test_compression_feasibility.py

@@ -151,15 +151,14 @@ def test_feasibility_check_passes_live_main_runtime():
         agent._emit_status = lambda msg: None
         agent._check_compression_model_feasibility()
 
-    mock_get_client.assert_called_once_with(
-        "compression",
-        main_runtime={
-            "model": "gpt-5.4",
-            "provider": "openai-codex",
+    # Called for both compression + flush_memories; verify compression call present
+    assert any(
+        c == (("compression",), {"main_runtime": {
+            "model": "gpt-5.4", "provider": "openai-codex",
             "base_url": "https://chatgpt.com/backend-api/codex",
-            "api_key": "codex-token",
-            "api_mode": "codex_responses",
-        },
+            "api_key": "codex-token", "api_mode": "codex_responses",
+        }})
+        for c in mock_get_client.call_args_list
     )
 
 
@@ -179,12 +178,12 @@ def test_feasibility_check_passes_config_context_length(mock_get_client, mock_ct
     agent._emit_status = lambda msg: None
     agent._check_compression_model_feasibility()
 
-    mock_ctx_len.assert_called_once_with(
-        "custom/big-model",
-        base_url="http://custom-endpoint:8080/v1",
-        api_key="sk-custom",
-        config_context_length=1_000_000,
-        provider="openrouter",
+    # First call is the compression model
+    assert mock_ctx_len.call_args_list[0] == (
+        ("custom/big-model",),
+        {"base_url": "http://custom-endpoint:8080/v1",
+         "api_key": "sk-custom", "config_context_length": 1_000_000,
+         "provider": "openrouter"},
     )
 
 
@@ -202,12 +201,11 @@ def test_feasibility_check_ignores_invalid_context_length(mock_get_client, mock_
     agent._emit_status = lambda msg: None
     agent._check_compression_model_feasibility()
 
-    mock_ctx_len.assert_called_once_with(
-        "custom/model",
-        base_url="http://custom:8080/v1",
-        api_key="sk-test",
-        config_context_length=None,
-        provider="openrouter",
+    assert mock_ctx_len.call_args_list[0] == (
+        ("custom/model",),
+        {"base_url": "http://custom:8080/v1",
+         "api_key": "sk-test", "config_context_length": None,
+         "provider": "openrouter"},
     )
 
 
@@ -255,13 +253,10 @@ def test_init_feasibility_check_uses_aux_context_override_from_config():
         )
 
     assert agent._aux_compression_context_length_config == 1_000_000
-    mock_ctx_len.assert_called_once_with(
-        "custom/big-model",
-        base_url="http://custom-endpoint:8080/v1",
-        api_key="sk-custom",
-        config_context_length=1_000_000,
-        provider="",
-    )
+    c0 = mock_ctx_len.call_args_list[0]
+    assert c0.args == ("custom/big-model",)
+    assert c0.kwargs["base_url"] == "http://custom-endpoint:8080/v1"
+    assert c0.kwargs["config_context_length"] == 1_000_000
 
 
 @patch("agent.auxiliary_client.get_text_auxiliary_client")
@@ -311,8 +306,10 @@ def test_exception_does_not_crash(mock_get_client):
 
 @patch("agent.model_metadata.get_model_context_length", return_value=100_000)
 @patch("agent.auxiliary_client.get_text_auxiliary_client")
-def test_exact_threshold_boundary_no_warning(mock_get_client, mock_ctx_len):
-    """No warning when aux context exactly equals the threshold."""
+def test_exact_threshold_boundary_triggers_headroom_correction(mock_get_client, mock_ctx_len):
+    """When aux context exactly equals the threshold, headroom deduction
+    still fires — flush_memories adds system prompt + tool schema on top
+    of the conversation messages, so threshold must be lowered."""
     agent = _make_agent(main_context=200_000, threshold_percent=0.50)
     mock_client = MagicMock()
     mock_client.base_url = "https://openrouter.ai/api/v1"
@@ -324,7 +321,10 @@ def test_exact_threshold_boundary_no_warning(mock_get_client, mock_ctx_len):
 
     agent._check_compression_model_feasibility()
 
-    assert len(messages) == 0
+    # 100K - headroom < 100K → auto-corrects
+    assert len(messages) == 1
+    assert "Auto-lowered" in messages[0]
+    assert agent.context_compressor.threshold_tokens < 100_000
 
 
 @patch("agent.model_metadata.get_model_context_length", return_value=99_999)

tests/run_agent/test_flush_memories_context_trim.py

@@ -0,0 +1,219 @@
+"""Tests for flush_memories context-overflow prevention.
+
+1. _check_compression_model_feasibility now also resolves the
+   flush_memories auxiliary model and uses min(compression, flush) as the
+   effective aux context.
+2. Headroom is always deducted before comparing aux_context vs threshold
+   (not only when aux_context < threshold).
+3. flush_memories() trims oversized conversations before the LLM call as
+   defence-in-depth for paths that bypass preflight compression.
+"""
+
+import sys
+import types
+from types import SimpleNamespace
+from unittest.mock import patch, MagicMock
+
+sys.modules.setdefault("fire", types.SimpleNamespace(Fire=lambda *a, **k: None))
+sys.modules.setdefault("firecrawl", types.SimpleNamespace(Firecrawl=object))
+sys.modules.setdefault("fal_client", types.SimpleNamespace())
+
+import run_agent
+
+
+# ── Helpers ──────────────────────────────────────────────────────────────
+
+
+class _FakeOpenAI:
+    def __init__(self, **kw):
+        self.api_key = kw.get("api_key", "test")
+        self.base_url = kw.get("base_url", "http://test")
+
+    def close(self):
+        pass
+
+
+def _make_agent(monkeypatch, **kw):
+    monkeypatch.setattr(run_agent, "get_tool_definitions", lambda **k: [
+        {"type": "function", "function": {
+            "name": "memory", "description": "m",
+            "parameters": {"type": "object", "properties": {
+                "action": {"type": "string"},
+                "target": {"type": "string"},
+                "content": {"type": "string"},
+            }},
+        }},
+    ])
+    monkeypatch.setattr(run_agent, "check_toolset_requirements", lambda: {})
+    monkeypatch.setattr(run_agent, "OpenAI", _FakeOpenAI)
+    agent = run_agent.AIAgent(
+        api_key="test-key", base_url="https://test.example.com/v1",
+        provider=kw.get("provider", "openrouter"),
+        api_mode=kw.get("api_mode", "chat_completions"),
+        max_iterations=4, quiet_mode=True,
+        skip_context_files=True, skip_memory=True,
+    )
+    agent._memory_store = MagicMock()
+    agent._memory_flush_min_turns = 1
+    agent._user_turn_count = 5
+    return agent
+
+
+def _make_msgs(n, chars=400):
+    return [{"role": "user" if i % 2 == 0 else "assistant",
+             "content": f"M{i}: " + "x" * max(0, chars - 6)}
+            for i in range(n)]
+
+
+def _noop_response():
+    return SimpleNamespace(
+        choices=[SimpleNamespace(
+            finish_reason="stop",
+            message=SimpleNamespace(content="Nothing.", tool_calls=None),
+        )],
+        usage=SimpleNamespace(prompt_tokens=50, completion_tokens=10, total_tokens=60),
+    )
+
+
+# ── Feasibility: flush model + always-deduct headroom ────────────────────
+
+
+class TestFeasibilityFixes:
+
+    def test_smaller_flush_model_lowers_effective_context(self, monkeypatch):
+        """flush_memories model with smaller context drives the threshold."""
+        agent = _make_agent(monkeypatch)
+        agent.context_compressor.context_length = 200_000
+        agent.context_compressor.threshold_tokens = 100_000
+
+        fc = SimpleNamespace(base_url="http://test", api_key="k")
+
+        def _aux(task, **kw):
+            if task == "compression":
+                return fc, "big-model"
+            return fc, "small-flush-model"
+
+        def _ctx(model, **kw):
+            return 200_000 if model == "big-model" else 80_000
+
+        with patch("agent.auxiliary_client.get_text_auxiliary_client", side_effect=_aux), \
+             patch("agent.model_metadata.get_model_context_length", side_effect=_ctx):
+            agent._check_compression_model_feasibility()
+
+        assert agent.context_compressor.threshold_tokens < 100_000
+
+    def test_same_model_overhead_still_triggers_correction(self, monkeypatch):
+        """The primary bug: aux == main model, aux_context > threshold, but
+        threshold + overhead > aux_context.  Headroom must fire even when
+        aux_context >= threshold."""
+        agent = _make_agent(monkeypatch)
+        agent.context_compressor.context_length = 128_000
+        agent.context_compressor.threshold_tokens = 120_000
+
+        fc = SimpleNamespace(base_url="http://test", api_key="k")
+
+        with patch("agent.auxiliary_client.get_text_auxiliary_client",
+                    return_value=(fc, "same-model")), \
+             patch("agent.model_metadata.get_model_context_length",
+                    return_value=128_000):
+            agent._check_compression_model_feasibility()
+
+        # 128K - headroom (~12.1K) ≈ 115.9K < 120K → threshold lowered
+        assert agent.context_compressor.threshold_tokens < 120_000
+
+    def test_flush_resolution_failure_is_non_fatal(self, monkeypatch):
+        """If flush model resolution raises, check proceeds with compression model."""
+        agent = _make_agent(monkeypatch)
+        agent.context_compressor.context_length = 200_000
+        agent.context_compressor.threshold_tokens = 100_000
+
+        fc = SimpleNamespace(base_url="http://test", api_key="k")
+        n = [0]
+
+        def _aux(task, **kw):
+            n[0] += 1
+            if task == "flush_memories":
+                raise RuntimeError("boom")
+            return fc, "model"
+
+        with patch("agent.auxiliary_client.get_text_auxiliary_client", side_effect=_aux), \
+             patch("agent.model_metadata.get_model_context_length", return_value=200_000):
+            agent._check_compression_model_feasibility()
+
+        assert n[0] == 2  # both tasks attempted
+
+
+# ── flush_memories trimming ──────────────────────────────────────────────
+
+
+class TestFlushMemoriesTrimming:
+
+    def test_oversized_conversation_trimmed(self, monkeypatch):
+        agent = _make_agent(monkeypatch)
+        agent._cached_system_prompt = "System."
+        messages = _make_msgs(200, chars=500)
+
+        fc = SimpleNamespace(base_url="http://test", api_key="k")
+        with patch("agent.auxiliary_client.get_text_auxiliary_client",
+                    return_value=(fc, "small")), \
+             patch("agent.model_metadata.get_model_context_length",
+                    return_value=8_000), \
+             patch("agent.auxiliary_client.call_llm",
+                    return_value=_noop_response()) as mock:
+            agent.flush_memories(messages)
+
+        sent = mock.call_args.kwargs.get("messages", [])
+        assert len(sent) < 100
+
+    def test_small_conversation_untouched(self, monkeypatch):
+        agent = _make_agent(monkeypatch)
+        agent._cached_system_prompt = "System."
+        messages = [
+            {"role": "user", "content": "Hi"},
+            {"role": "assistant", "content": "Hey"},
+            {"role": "user", "content": "Save"},
+        ]
+
+        fc = SimpleNamespace(base_url="http://test", api_key="k")
+        with patch("agent.auxiliary_client.get_text_auxiliary_client",
+                    return_value=(fc, "big")), \
+             patch("agent.model_metadata.get_model_context_length",
+                    return_value=200_000), \
+             patch("agent.auxiliary_client.call_llm",
+                    return_value=_noop_response()) as mock:
+            agent.flush_memories(messages)
+
+        sent = mock.call_args.kwargs.get("messages", [])
+        assert len(sent) == 5  # sys + 3 conv + flush
+
+    def test_trim_failure_does_not_block_flush(self, monkeypatch):
+        agent = _make_agent(monkeypatch)
+        messages = _make_msgs(10, chars=100)
+
+        with patch("agent.auxiliary_client.get_text_auxiliary_client",
+                    side_effect=RuntimeError("no provider")), \
+             patch("agent.auxiliary_client.call_llm",
+                    return_value=_noop_response()) as mock:
+            agent.flush_memories(messages)
+            assert mock.called
+
+    def test_sentinel_cleaned_after_trim(self, monkeypatch):
+        agent = _make_agent(monkeypatch)
+        messages = [
+            {"role": "user", "content": "Hi"},
+            {"role": "assistant", "content": "Hey"},
+            {"role": "user", "content": "Save"},
+        ]
+        n = len(messages)
+
+        fc = SimpleNamespace(base_url="http://test", api_key="k")
+        with patch("agent.auxiliary_client.get_text_auxiliary_client",
+                    return_value=(fc, "m")), \
+             patch("agent.model_metadata.get_model_context_length",
+                    return_value=128_000), \
+             patch("agent.auxiliary_client.call_llm",
+                    return_value=_noop_response()):
+            agent.flush_memories(messages)
+
+        assert len(messages) == n
+        assert not any(m.get("_flush_sentinel") for m in messages)