feat: improve error handling and model limit detection

- Add automatic model limit learning from SDK errors
- Improve error diagnostics with detailed SDK error payload
- Add resilient chat selection (reset stale chat IDs)
- Filter non-existent sub-chats from open tabs
- Enhanced error parsing with JSON support and multiple patterns
- Add raw payload logging for unknown error formats
- Clamp maxThinkingTokens to model-specific limits automatically
- Disable extended thinking for Opus 4.5 (64k limit)

Author: evgyur

package-lock.json

@@ -8,7 +8,8 @@
 import { spawn } from 'child_process'
 import { fileURLToPath } from 'url'
 import { dirname, join } from 'path'
-import { existsSync } from 'fs'
+import { existsSync, mkdirSync, copyFileSync } from 'fs'
+import { execSync } from 'child_process'
 
 const __filename = fileURLToPath(import.meta.url)
 const __dirname = dirname(__filename)
@@ -111,6 +112,35 @@ electronBuilder.on('close', (code) => {
     console.log('   Please close 1Code.exe and try again')
     process.exit(1)
   } else if (existsSync(exePath)) {
+    // Fix: Ensure better-sqlite3 build directory is complete
+    const betterSqlite3BuildSource = join(projectRoot, 'node_modules', 'better-sqlite3', 'build')
+    const betterSqlite3BuildDest = join(projectRoot, 'release', 'win-unpacked', 'resources', 'app.asar.unpacked', 'node_modules', 'better-sqlite3', 'build')
+    const betterSqlite3NodeFile = join(betterSqlite3BuildDest, 'Release', 'better_sqlite3.node')
+
+    if (existsSync(betterSqlite3BuildSource) && !existsSync(betterSqlite3NodeFile)) {
+      try {
+        // Use robocopy to copy entire build directory structure
+        const robocopyCmd = `robocopy "${betterSqlite3BuildSource}" "${betterSqlite3BuildDest}" /E /NFL /NDL /NJH /NJS`
+        execSync(robocopyCmd, { cwd: projectRoot, stdio: 'ignore' })
+        if (existsSync(betterSqlite3NodeFile)) {
+          console.log('\n✓ Fixed: Copied better-sqlite3 build directory')
+        }
+      } catch (err) {
+        // Fallback: try manual copy
+        try {
+          const betterSqlite3Source = join(betterSqlite3BuildSource, 'Release', 'better_sqlite3.node')
+          const betterSqlite3DestDir = join(betterSqlite3BuildDest, 'Release')
+          if (existsSync(betterSqlite3Source)) {
+            mkdirSync(betterSqlite3DestDir, { recursive: true })
+            copyFileSync(betterSqlite3Source, betterSqlite3NodeFile)
+            console.log('\n✓ Fixed: Copied better-sqlite3 native bindings')
+          }
+        } catch (err2) {
+          console.log('\n⚠️  Warning: Could not copy better-sqlite3 native bindings:', err2.message)
+        }
+      }
+    }
+
     console.log('\n✅ Build completed successfully!')
     console.log(`   Executable: ${exePath}`)
     process.exit(0)

scripts/package-windows.mjs

@@ -11,6 +11,7 @@ declare global {
     // Renderer process (VITE_ prefix)
     readonly VITE_POSTHOG_KEY?: string
     readonly VITE_POSTHOG_HOST?: string
+    readonly VITE_SENTRY_DSN?: string
   }
 }
 

src/env.d.ts

@@ -117,8 +117,22 @@ export async function initAutoUpdater(getWindow: () => BrowserWindow | null) {
 
   // Event: Error
   autoUpdater.on("error", (error: Error) => {
-    log.error("[AutoUpdater] Error:", error.message)
-    sendToRenderer("update:error", error.message)
+    // Check if this is a 404 error (update manifest not found)
+    // This is normal for local builds or when updates aren't published yet
+    const is404Error = error.message.includes("404") || 
+                       error.message.includes("latest.yml") ||
+                       error.message.includes("Cannot find channel")
+    
+    if (is404Error) {
+      log.info("[AutoUpdater] Update manifest not found (404) - this is normal for local builds")
+      // Treat 404 as "no update available" rather than an error
+      sendToRenderer("update:not-available", {
+        version: app.getVersion(),
+      })
+    } else {
+      log.error("[AutoUpdater] Error:", error.message)
+      sendToRenderer("update:error", error.message)
+    }
   })
 
   // Register IPC handlers

src/main/lib/auto-updater.ts

@@ -859,6 +859,13 @@ export const claudeRouter = router({
                 if (msgAny.type === "error" || msgAny.error) {
                   const sdkError =
                     msgAny.error || msgAny.message || "Unknown SDK error"
+                  const sdkErrorPayload = {
+                    type: msgAny.type,
+                    error: msgAny.error,
+                    message: msgAny.message,
+                    code: msgAny.code,
+                    status: msgAny.status,
+                  }
                   lastError = new Error(sdkError)
 
                   // Categorize SDK-level errors
@@ -901,10 +908,11 @@ export const claudeRouter = router({
                   } else {
                     safeEmit({
                       type: "error",
-                      errorText: errorContext,
+                      errorText: `${errorContext}: ${sdkError}`,
                       debugInfo: {
                         category: errorCategory,
                         sdkError: sdkError,
+                        sdkErrorPayload,
                         sessionId: msgAny.session_id,
                         messageId: msgAny.message?.id,
                       },

src/main/lib/trpc/routers/claude.ts

@@ -7,6 +7,7 @@ import {
   clipboard,
   session,
   Menu,
+  nativeImage,
 } from "electron"
 import { join } from "path"
 import { readFileSync, existsSync } from "fs"
@@ -63,15 +64,64 @@ function registerIpcHandlers(getWindow: () => BrowserWindow | null): void {
   })
   // Note: Update checking is now handled by auto-updater module (lib/auto-updater.ts)
   ipcMain.handle("app:set-badge", (_event, count: number | null) => {
+    const win = getWindow()
     if (process.platform === "darwin") {
+      // macOS: Use dock badge
       app.dock.setBadge(count ? String(count) : "")
+    } else if (process.platform === "win32" && win) {
+      // Windows: Use overlay icon with number badge
+      if (count !== null && count > 0) {
+        // Request badge icon from renderer (it will generate and send via IPC)
+        // For now, show count in window title as fallback
+        win.setTitle(`1Code (${count})`)
+        // The actual overlay icon will be set when renderer sends the image data
+      } else {
+        win.setTitle("1Code")
+        // Clear overlay icon
+        win.setOverlayIcon(null, "")
+      }
+    }
+  })
+  
+  // Handle badge icon data from renderer (Windows overlay icon)
+  ipcMain.handle("app:set-badge-icon", (_event, imageData: string | null) => {
+    const win = getWindow()
+    if (process.platform === "win32" && win) {
+      if (imageData) {
+        // Convert data URL to native image
+        const image = nativeImage.createFromDataURL(imageData)
+        win.setOverlayIcon(image, `${imageData ? "New messages" : ""}`)
+      } else {
+        win.setOverlayIcon(null, "")
+      }
     }
   })
   ipcMain.handle(
     "app:show-notification",
     (_event, options: { title: string; body: string }) => {
       const { Notification } = require("electron")
-      new Notification(options).show()
+      // Electron Notification uses native Windows Notification API
+      // This will show a standard Windows desktop notification
+      const notification = new Notification({
+        title: options.title,
+        body: options.body,
+        // Windows-specific options
+        ...(process.platform === "win32" && {
+          // Use Windows 10+ action center
+          silent: false, // Play notification sound
+        }),
+      })
+      notification.show()
+      
+      // Optional: Handle notification click
+      notification.on("click", () => {
+        // Focus the main window when notification is clicked
+        const win = getWindow()
+        if (win) {
+          if (win.isMinimized()) win.restore()
+          win.focus()
+        }
+      })
     },
   )
 

src/main/windows/main.ts

@@ -1,12 +1,9 @@
 import { contextBridge, ipcRenderer } from "electron"
 import { exposeElectronTRPC } from "trpc-electron/main"
 
-// Only initialize Sentry in production to avoid IPC errors in dev mode
-if (process.env.NODE_ENV === "production") {
-  import("@sentry/electron/renderer").then((Sentry) => {
-    Sentry.init()
-  })
-}
+// Note: Sentry should NOT be initialized in preload script
+// Preload runs in isolated context and Sentry IPC won't work here
+// Sentry is initialized in main process and renderer process only
 
 // Expose tRPC IPC bridge for type-safe communication
 exposeElectronTRPC()
@@ -105,6 +102,7 @@ contextBridge.exposeInMainWorld("desktopApi", {
 
   // Native features
   setBadge: (count: number | null) => ipcRenderer.invoke("app:set-badge", count),
+  setBadgeIcon: (imageData: string | null) => ipcRenderer.invoke("app:set-badge-icon", imageData),
   showNotification: (options: { title: string; body: string }) =>
     ipcRenderer.invoke("app:show-notification", options),
   openExternal: (url: string) => ipcRenderer.invoke("shell:open-external", url),
@@ -208,6 +206,7 @@ export interface DesktopApi {
   toggleDevTools: () => Promise<void>
   setAnalyticsOptOut: (optedOut: boolean) => Promise<void>
   setBadge: (count: number | null) => Promise<void>
+  setBadgeIcon: (imageData: string | null) => Promise<void>
   showNotification: (options: { title: string; body: string }) => Promise<void>
   openExternal: (url: string) => Promise<void>
   getApiBaseUrl: () => Promise<string>

src/preload/index.ts

@@ -3,6 +3,7 @@ import { useState, useEffect } from "react"
 import {
   extendedThinkingEnabledAtom,
   soundNotificationsEnabledAtom,
+  desktopNotificationsEnabledAtom,
   analyticsOptOutAtom,
   ctrlTabTargetAtom,
   useNativeFrameAtom,
@@ -39,6 +40,7 @@ export function AgentsPreferencesTab() {
     extendedThinkingEnabledAtom,
   )
   const [soundEnabled, setSoundEnabled] = useAtom(soundNotificationsEnabledAtom)
+  const [desktopNotificationsEnabled, setDesktopNotificationsEnabled] = useAtom(desktopNotificationsEnabledAtom)
   const [analyticsOptOut, setAnalyticsOptOut] = useAtom(analyticsOptOutAtom)
   const [ctrlTabTarget, setCtrlTabTarget] = useAtom(ctrlTabTargetAtom)
   const [useNativeFrame, setUseNativeFrame] = useAtom(useNativeFrameAtom)
@@ -121,6 +123,24 @@ export function AgentsPreferencesTab() {
             </div>
             <Switch checked={soundEnabled} onCheckedChange={setSoundEnabled} />
           </div>
+
+          {/* Desktop Notifications Toggle (Windows) */}
+          {isWindows && (
+            <div className="flex items-start justify-between">
+              <div className="flex flex-col space-y-1">
+                <span className="text-sm font-medium text-foreground">
+                  Desktop Notifications
+                </span>
+                <span className="text-xs text-muted-foreground">
+                  Show Windows desktop notification when agent completes work
+                </span>
+              </div>
+              <Switch
+                checked={desktopNotificationsEnabled}
+                onCheckedChange={setDesktopNotificationsEnabled}
+              />
+            </div>
+          )}
         </div>
       </div>