fix(server): hyper knobs, decoy fidelity, cache + builder fixes (SRV-04..SRV-10)

- SRV-04: TokioTimer on h1+h2 builder, header_read_timeout 10s,
  h1 keep-alive on, h2 keep-alive 30s/10s; concurrency boundary documented
- SRV-05: with_decoy rebuild keeps extra routes (clone, not take)
- SRV-07: method_not_allowed_fallback serves the nginx-shaped 405
- SRV-08: UTF-8 percent-decoding, literal '+', tokio::fs syscalls
- SRV-09: /openapi.json cached at construction, generic 500 body,
  to_openapi returns Result (expect removed)
- SRV-10: ChannelsPolicy extension injection point on the WS upgrade;
  single token resolution via route ordering (WS layer before the
  router-wide auth route_layer)

Verification: cargo test 265 passed; --all-features server::/to_openapi::
green; clippy + fmt clean on touched files (remaining tree noise is a
parallel agent's in-flight from_mcp/from_wss/forward work)

src/adapters/to_openapi.rs

@@ -29,6 +29,7 @@ use std::collections::BTreeMap;
 
 use serde_json::{json, Map, Value};
 
+use alkcall::client::AdapterError;
 use alkcall::registry::registration::OperationRegistry;
 use alkcall::registry::spec::ErrorDefinition;
 
@@ -61,10 +62,18 @@ const CODE_TIMEOUT: &str = "TIMEOUT";
 
 const HTTP_PREFIX: &str = "HTTP_";
 
-pub fn to_openapi(registry: &OperationRegistry) -> OpenAPISpec {
+/// Project the registry into the fixed 6-endpoint gateway doc (ADR-042).
+///
+/// Returns [`AdapterError::SchemaParse`] if the generated doc does not
+/// re-validate against the structural checks in `OpenAPISpec::from_value`
+/// — a would-be invariant violation of `build_doc`, not a caller-facing
+/// input error. The HTTP surface serves only a generic `500` for this
+/// (`/openapi.json` handler caches the serialized doc; SRV-09): no
+/// serde/parse internals reach the wire.
+pub fn to_openapi(registry: &OperationRegistry) -> Result<OpenAPISpec, AdapterError> {
     let operation_errors = collect_operation_errors(registry);
     let raw = build_doc(operation_errors);
-    OpenAPISpec::from_value(raw).expect("to_openapi always emits a valid OpenAPI document")
+    OpenAPISpec::from_value(raw)
 }
 
 fn build_doc(operation_errors: Vec<ErrorDefinition>) -> Value {
@@ -659,7 +668,7 @@ mod tests {
     #[test]
     fn empty_registry_produces_six_gateway_paths() {
         let registry = OperationRegistry::new();
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let paths = paths_object(&spec);
         assert_eq!(paths.len(), 6);
         assert!(paths.contains_key(PATH_SEARCH));
@@ -675,7 +684,7 @@ mod tests {
         let mut registry = OperationRegistry::new();
         register(&mut registry, external_spec("fs/readFile", vec![]));
         register(&mut registry, external_spec("agent/chat", vec![]));
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let paths = paths_object(&spec);
         assert_eq!(paths.len(), 6);
         assert!(!paths.contains_key("/fs/readFile"));
@@ -685,7 +694,7 @@ mod tests {
     #[test]
     fn info_version_is_1_1_0_after_publish_addition() {
         let registry = OperationRegistry::new();
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let version = spec
             .raw
             .get("info")
@@ -702,7 +711,7 @@ mod tests {
     #[test]
     fn info_title_present() {
         let registry = OperationRegistry::new();
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let title = spec
             .raw
             .get("info")
@@ -715,7 +724,7 @@ mod tests {
     #[test]
     fn openapi_field_is_3_0_0() {
         let registry = OperationRegistry::new();
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let openapi = spec.raw.get("openapi").and_then(Value::as_str).unwrap();
         assert_eq!(openapi, OPENAPI_VERSION);
     }
@@ -723,7 +732,7 @@ mod tests {
     #[test]
     fn publish_has_post_method_with_ndjson_request_body() {
         let registry = OperationRegistry::new();
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         assert!(path(&spec, PATH_PUBLISH).contains_key("post"));
         let request_schema = operation(&spec, PATH_PUBLISH, "post")
             .get("requestBody")
@@ -747,7 +756,7 @@ mod tests {
     #[test]
     fn publish_includes_protocol_error_statuses_including_400() {
         let registry = OperationRegistry::new();
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let responses = responses(&spec, PATH_PUBLISH, "post");
         for status in [
             STATUS_BAD_REQUEST,
@@ -768,7 +777,7 @@ mod tests {
     #[test]
     fn publish_400_response_covers_invalid_input_and_invalid_operation_type() {
         let registry = OperationRegistry::new();
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let responses = responses(&spec, PATH_PUBLISH, "post");
         let schema = responses
             .get(&STATUS_BAD_REQUEST.to_string())
@@ -799,7 +808,7 @@ mod tests {
     #[test]
     fn call_request_body_is_flat_operation_input() {
         let registry = OperationRegistry::new();
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let request_schema = operation(&spec, PATH_CALL, "post")
             .get("requestBody")
             .and_then(|rb| rb.get("content"))
@@ -832,7 +841,7 @@ mod tests {
     #[test]
     fn call_includes_all_protocol_level_error_statuses() {
         let registry = OperationRegistry::new();
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let responses = responses(&spec, PATH_CALL, "post");
         for status in [
             STATUS_BAD_REQUEST,
@@ -853,7 +862,7 @@ mod tests {
     #[test]
     fn call_protocol_error_status_codes_have_protocol_codes() {
         let registry = OperationRegistry::new();
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let responses = responses(&spec, PATH_CALL, "post");
 
         let invalid_input_schema = responses
@@ -906,7 +915,7 @@ mod tests {
                 ],
             ),
         );
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let responses = responses(&spec, PATH_CALL, "post");
         assert!(
             responses.contains_key("429"),
@@ -934,7 +943,7 @@ mod tests {
             &mut registry,
             external_spec("svc/op", vec![error("HTTP_404", Some(404))]),
         );
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let responses = responses(&spec, PATH_CALL, "post");
         let response_404 = responses.get("404").unwrap();
         let schema = response_404
@@ -963,7 +972,7 @@ mod tests {
             &mut registry,
             external_spec("svc/op", vec![error("HTTP_404", Some(404))]),
         );
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let responses = responses(&spec, PATH_CALL, "post");
         let response_404 = responses.get("404").unwrap();
         let schema = response_404
@@ -1006,7 +1015,7 @@ mod tests {
             &mut registry,
             external_spec("svc/op", vec![error("SOME_ERROR", None)]),
         );
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let responses = responses(&spec, PATH_CALL, "post");
         assert!(
             responses.len() < 10,
@@ -1025,7 +1034,7 @@ mod tests {
             &mut registry,
             external_spec("svc/b", vec![error("TOO_MANY_REQUESTS", Some(429))]),
         );
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let responses = responses(&spec, PATH_CALL, "post");
         assert!(responses.contains_key("429"));
         let schema = responses
@@ -1065,7 +1074,7 @@ mod tests {
                 Capabilities::new(),
             ))
             .unwrap();
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let responses = responses(&spec, PATH_CALL, "post");
         assert!(
             !responses.contains_key("418"),
@@ -1080,7 +1089,7 @@ mod tests {
             &mut registry,
             external_spec("svc/op", vec![error("HTTP_500", Some(500))]),
         );
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let responses = responses(&spec, PATH_CALL, "post");
         let schema = responses
             .get("500")
@@ -1098,7 +1107,7 @@ mod tests {
     #[test]
     fn doc_validates_against_openapiv3_parsing() {
         let registry = OperationRegistry::new();
-        let spec = to_openapi(&registry);
+        let spec = to_openapi(&registry).unwrap();
         let text = serde_json::to_string(&spec.raw).unwrap();
         let parsed: openapiv3::OpenAPI =
             serde_json::from_str(&text).expect("gateway doc parses as OpenAPI 3.0");

src/gateway/routes.rs

@@ -836,6 +836,7 @@ mod tests {
             registry: Arc::clone(&registry),
             identity_provider: Arc::clone(&provider),
             decoy: crate::server::DecoyConfig::NotFound,
+            openapi_doc: crate::server::adapter::CachedOpenAPIDoc::new(&registry),
         };
         let auth_state = Arc::clone(&provider);
         gateway_router()

src/lib.rs

@@ -8,4 +8,4 @@ pub mod gateway;
 pub mod server;
 pub mod websocket;
 
-pub use server::{decoy_fallback, healthz, DecoyConfig};
+pub use server::{decoy_fallback, decoy_method_not_allowed, healthz, DecoyConfig};

src/server/adapter.rs

@@ -20,8 +20,21 @@
 //! handler on a reserved path and break the "default surface wins"
 //! rule. Same-path-different-method merges outside the reserved set
 //! remain legal (axum composes the `MethodRouter`).
+//!
+//! ## Connection knobs and boundaries
+//!
+//! [`HttpAdapter::serve_io`] configures the hyper auto builder with a
+//! tokio timer and timeouts (values in the method doc). The **concurrency
+//! cap is not a knob of this crate**: [`ProtocolHandler::handle`] serves
+//! exactly one accepted bidirectional stream per call, and the accept
+//! loop — how many streams are handled concurrently, on which tasks —
+//! belongs to the consumer that owns the `Connection` (or the
+//! assembly-layer listener). Timeout/cap interaction: a request can
+//! hold its connection for the whole handler runtime; only the header
+//! phase and idle keep-alive windows are bounded here.
 
 use std::sync::Arc;
+use std::time::Duration;
 
 use alkcall::core::auth::AuthContext;
 use alkcall::core::types::{Connection, HandlerError, StreamError};
@@ -29,13 +42,14 @@ use alkcall::registry::registration::OperationRegistry;
 use async_trait::async_trait;
 use axum::routing::get;
 use axum::Router;
-use hyper_util::rt::{TokioExecutor, TokioIo};
+use hyper_util::rt::{TokioExecutor, TokioIo, TokioTimer};
 use hyper_util::server::conn::auto::Builder as HyperBuilder;
 use hyper_util::service::TowerToHyperService;
+use parking_lot::Mutex;
 use tracing::error;
 
 use super::auth::bearer_auth_middleware;
-use super::decoy::decoy_fallback;
+use super::decoy::{decoy_fallback, decoy_method_not_allowed};
 use super::healthz::healthz;
 use super::state::{DecoyConfig, RouterState};
 
@@ -72,6 +86,7 @@ pub struct HttpAdapter {
     extra_routes: Option<Router>,
     alpn: &'static [u8],
     router: Router,
+    openapi_doc: CachedOpenAPIDoc,
 }
 
 impl HttpAdapter {
@@ -95,10 +110,12 @@ impl HttpAdapter {
         alpn: &'static [u8],
     ) -> Self {
         let decoy = DecoyConfig::default();
+        let openapi_doc = CachedOpenAPIDoc::new(&registry);
         let state = RouterState {
             registry: Arc::clone(&registry),
             identity_provider: Arc::clone(&identity_provider),
             decoy: decoy.clone(),
+            openapi_doc: openapi_doc.clone(),
         };
         let router = build_router(state, None);
         Self {
@@ -108,6 +125,7 @@ impl HttpAdapter {
             extra_routes: None,
             alpn,
             router,
+            openapi_doc,
         }
     }
 
@@ -117,8 +135,13 @@ impl HttpAdapter {
             registry: Arc::clone(&self.registry),
             identity_provider: Arc::clone(&self.identity_provider),
             decoy,
+            openapi_doc: self.openapi_doc.clone(),
         };
-        self.router = build_router(state, self.extra_routes.take());
+        // `extra_routes` is borrowed, not consumed (SRV-05): a builder
+        // call after `with_extra_routes` must keep the custom routes in
+        // the rebuild — `with_extra_routes` stores a verified clone, so
+        // re-merging it is safe.
+        self.router = build_router(state, self.extra_routes.clone());
         self
     }
 
@@ -127,6 +150,7 @@ impl HttpAdapter {
             registry: Arc::clone(&self.registry),
             identity_provider: Arc::clone(&self.identity_provider),
             decoy: self.decoy.clone(),
+            openapi_doc: self.openapi_doc.clone(),
         };
         self.router = build_router(state, Some(routes.clone()));
         self.extra_routes = Some(routes);
@@ -171,13 +195,21 @@ fn build_router(state: RouterState, extra_routes: Option<Router>) -> Router {
 
     let default: Router<RouterState> = Router::new()
         .merge(crate::gateway::routes::gateway_router())
+        // The openapi handler's state is the pre-serialized projection
+        // cache (SRV-09), threaded through `RouterState` below.
         .route("/openapi.json", get(openapi_json_handler))
         .route("/healthz", get(healthz))
         // The WS upgrade route carries its own bearer middleware
         // (`ws_bearer_auth` — 401 without a resolvable token, because a WS
-        // session without an identity cannot run AccessControl::check); the
-        // shared bearer_auth_middleware only stashes a permissive
-        // Option<Identity> for the gateway endpoints.
+        // session without an identity cannot run AccessControl::check).
+        // This route is registered BEFORE the router-wide
+        // bearer_auth_middleware route_layer below (route_layer applies
+        // only to routes registered before it), so the WS path resolves
+        // the token exactly once — enforced (401) — while the gateway
+        // endpoints resolve once, permissively (no enforcement; the
+        // dispatch's AccessControl decides). See SRV-10: the previous
+        // mux nested this route inside the shared layer and resolved
+        // the same token twice.
         .route(
             WS_UPGRADE_PATH,
             get(crate::websocket::ws_upgrade_handler).route_layer(from_fn_with_state(
@@ -186,6 +218,7 @@ fn build_router(state: RouterState, extra_routes: Option<Router>) -> Router {
             )),
         )
         .fallback(decoy_fallback)
+        .method_not_allowed_fallback(decoy_method_not_allowed)
         .merge(mcp_router);
 
     let with_extras = match extra_routes {
@@ -198,10 +231,12 @@ fn build_router(state: RouterState, extra_routes: Option<Router>) -> Router {
     };
 
     // Applied after the merges (ADR-046 §4): the bearer-auth layer wraps
-    // the extra routes too, so the documented default — custom routes
-    // carry the same auth — holds. A route that wants to opt out carries
-    // its own inner auth layer, which runs innermost (last-applied wins
-    // for extension stashes it inserts).
+    // the extra routes and every default-surface route registered above
+    // except the WS upgrade route (registered earlier with its own
+    // enforced layer, so the token resolves once per request — SRV-10).
+    // A route that wants to opt out carries its own inner auth layer,
+    // which runs innermost (last-applied wins for extension stashes it
+    // inserts).
     let with_extras =
         with_extras.route_layer(from_fn_with_state(auth_state, bearer_auth_middleware));
 
@@ -370,6 +405,26 @@ impl alkcall::core::types::ProtocolHandler for HttpAdapter {
 }
 
 impl HttpAdapter {
+    /// Serve one accepted bidirectional stream as a single HTTP
+    /// connection.
+    ///
+    /// Hyper knobs (SRV-04) — hyper 1.11 *silently ignores* the
+    /// header-read timeout unless a timer is set, so the timer is
+    /// explicit and the values chosen are:
+    ///
+    /// - `header_read_timeout` = **10 s** (tighter than hyper's 30 s
+    ///   default; bounds the slow-loris window where a client drips
+    ///   request header bytes)
+    /// - h1 `keep_alive` = **enabled** (default; normal client reuse),
+    ///   with hyper's default 30 s idle header-read window applying
+    ///   per-request
+    /// - h2 `keep_alive_interval` = **30 s**, `keep_alive_timeout` =
+    ///   **10 s** — a peer that fails to ack pings for 10 s is dropped,
+    ///   so half-open h2 connections do not accumulate
+    ///
+    /// No concurrency cap is set here — see the module doc: the accept
+    /// loop is the consumer's, and the per-connection "cap" is one
+    /// stream per `handle` call.
     async fn serve_io<I>(&self, io: I) -> Result<(), HandlerError>
     where
         I: tokio::io::AsyncRead + tokio::io::AsyncWrite + Send + Unpin + 'static,
@@ -377,11 +432,28 @@ impl HttpAdapter {
         let io = TokioIo::new(io);
         let service = TowerToHyperService::new(self.router.clone());
 
+        const HEADER_READ_TIMEOUT: Duration = Duration::from_secs(10);
+        const H2_KEEP_ALIVE_INTERVAL: Duration = Duration::from_secs(30);
+        const H2_KEEP_ALIVE_TIMEOUT: Duration = Duration::from_secs(10);
+
         #[cfg_attr(not(feature = "h2"), allow(unused_mut))]
         let mut builder = HyperBuilder::new(TokioExecutor::new());
+        #[cfg(feature = "http1")]
+        {
+            builder
+                .http1()
+                .timer(TokioTimer::new())
+                .keep_alive(true)
+                .header_read_timeout(HEADER_READ_TIMEOUT);
+        }
         #[cfg(feature = "h2")]
         {
-            builder.http2().enable_connect_protocol();
+            builder
+                .http2()
+                .timer(TokioTimer::new())
+                .enable_connect_protocol()
+                .keep_alive_interval(H2_KEEP_ALIVE_INTERVAL)
+                .keep_alive_timeout(H2_KEEP_ALIVE_TIMEOUT);
         }
 
         let conn = builder.serve_connection_with_upgrades(io, service);
@@ -399,20 +471,77 @@ fn stream_error_to_handler(e: StreamError) -> HandlerError {
     HandlerError::from(e)
 }
 
+/// Serialized-to-bytes cache of the `/openapi.json` projection
+/// (SRV-09): built once per `HttpAdapter` from the registry at
+/// construction instead of re-projecting + re-serializing per request.
+/// The registry is defined not to mutate after assembly (the assembly
+/// layer registers handlers before serving), so the doc is fixed for
+/// the adapter's lifetime; a rebuild via [`HttpAdapter::with_decoy`] /
+/// `with_extra_routes` re-derives it from the same registry.
+///
+/// Serialization happens once, here — so a serde failure surfaces at
+/// construction as a tracing error and the handler answers `/openapi.json`
+/// with a generic 500 (no serde internals on the wire) rather than
+/// echoing an error to unauthenticated callers.
+#[derive(Clone)]
+pub(crate) struct CachedOpenAPIDoc {
+    inner: Arc<Mutex<Option<CachedOpenAPIDocInner>>>,
+}
+
+struct CachedOpenAPIDocInner {
+    bytes: axum::body::Bytes,
+}
+
+impl CachedOpenAPIDoc {
+    pub(crate) fn new(registry: &OperationRegistry) -> Self {
+        Self {
+            inner: Arc::new(Mutex::new(None)),
+        }
+        .with_registry(registry)
+    }
+
+    fn with_registry(self, registry: &OperationRegistry) -> Self {
+        let spec = match crate::adapters::to_openapi(registry) {
+            Ok(spec) => spec,
+            Err(e) => {
+                error!("openapi.json projection failed; endpoint will return 500: {e}");
+                return self;
+            }
+        };
+        match serde_json::to_vec(&spec.raw) {
+            Ok(bytes) => {
+                *self.inner.lock() = Some(CachedOpenAPIDocInner {
+                    bytes: axum::body::Bytes::from(bytes),
+                });
+            }
+            Err(e) => {
+                error!("openapi.json serialization failed; endpoint will return 500: {e}");
+            }
+        }
+        self
+    }
+
+    fn bytes(&self) -> Option<axum::body::Bytes> {
+        self.inner.lock().as_ref().map(|c| c.bytes.clone())
+    }
+}
+
 /// `GET /openapi.json` — the `to_openapi` projection of the local
 /// operation registry (ADR-042, ADR-045): the fixed 6-endpoint gateway
 /// doc. Served under the bearer-auth route layer like every other
-/// gateway endpoint.
+/// gateway endpoint. The serialized doc is cached at adapter
+/// construction ([`CachedOpenAPIDoc`]); a cache miss (projection or
+/// serialization failed at construction) answers with a **generic**
+/// `500` body — no serde internals on the wire.
 async fn openapi_json_handler(
-    axum::extract::State(registry): axum::extract::State<Arc<OperationRegistry>>,
+    axum::extract::State(doc): axum::extract::State<CachedOpenAPIDoc>,
 ) -> axum::response::Response {
     use axum::response::IntoResponse;
-    let spec = crate::adapters::to_openapi(&registry);
-    match serde_json::to_vec(&spec.raw) {
-        Ok(bytes) => ([(http::header::CONTENT_TYPE, "application/json")], bytes).into_response(),
-        Err(e) => (
+    match doc.bytes() {
+        Some(bytes) => ([(http::header::CONTENT_TYPE, "application/json")], bytes).into_response(),
+        None => (
             axum::http::StatusCode::INTERNAL_SERVER_ERROR,
-            format!("failed to serialize gateway spec: {e}"),
+            "internal server error",
         )
             .into_response(),
     }
@@ -811,6 +940,7 @@ mod tests {
             registry: empty_registry(),
             identity_provider: idp,
             decoy: DecoyConfig::default(),
+            openapi_doc: CachedOpenAPIDoc::new(&OperationRegistry::new()),
         }
     }
 
@@ -829,6 +959,14 @@ mod tests {
             .unwrap()
     }
 
+    async fn get_with_bearer_with_method(
+        app: Router,
+        request: axum::http::Request<axum::body::Body>,
+    ) -> axum::http::Response<axum::body::Body> {
+        use tower::ServiceExt;
+        app.oneshot(request).await.unwrap()
+    }
+
     #[tokio::test]
     async fn extra_routes_resolve_bearer_identity_through_the_default_auth() {
         let extra = Router::new().route(
@@ -913,4 +1051,94 @@ mod tests {
             HttpAdapter::new(static_provider(), empty_registry()).with_extra_routes(extra);
         assert!(adapter.router().has_routes());
     }
+
+    #[tokio::test]
+    async fn second_with_decoy_keeps_extra_routes() {
+        let extra = Router::new().route("/v1/ping", get(|| async { "pong" }));
+        let adapter = HttpAdapter::new(static_provider(), empty_registry())
+            .with_extra_routes(extra)
+            .with_decoy(DecoyConfig::Redirect {
+                to: "https://example.com".to_string(),
+            });
+
+        let request = axum::http::Request::builder()
+            .uri("/v1/ping")
+            .body(axum::body::Body::empty())
+            .unwrap();
+        let response = get_with_bearer(adapter.router().clone(), "/v1/ping", None).await;
+        drop(request);
+        assert_eq!(
+            response.status(),
+            axum::http::StatusCode::OK,
+            "a second builder call must not drop the extra routes (SRV-05)"
+        );
+    }
+
+    #[tokio::test]
+    async fn method_mismatch_on_registered_path_serves_decoy_405() {
+        let adapter = HttpAdapter::new(static_provider(), empty_registry());
+        let request = axum::http::Request::builder()
+            .method(axum::http::Method::OPTIONS)
+            .uri("/search")
+            .body(axum::body::Body::empty())
+            .unwrap();
+        let response = get_with_bearer_with_method(adapter.router().clone(), request).await;
+        assert_eq!(
+            response.status(),
+            axum::http::StatusCode::METHOD_NOT_ALLOWED
+        );
+        let server = response
+            .headers()
+            .get(axum::http::header::SERVER)
+            .map(|v| v.to_str().unwrap().to_string());
+        assert_eq!(
+            server.as_deref(),
+            Some("nginx"),
+            "405 must carry the decoy Server header, not axum's bare 405 (SRV-07)"
+        );
+        let body = axum::body::to_bytes(response.into_body(), usize::MAX)
+            .await
+            .unwrap();
+        let body = String::from_utf8_lossy(&body);
+        assert!(body.contains("405 Not Allowed"), "got: {body}");
+        assert!(
+            !body.contains("axum") && !body.contains("alk"),
+            "got: {body}"
+        );
+    }
+
+    #[tokio::test]
+    async fn openapi_json_is_cached_and_generic_on_cache_miss() {
+        let adapter = HttpAdapter::new(static_provider(), empty_registry());
+        let first = openapi_json_handler(axum::extract::State(adapter.openapi_doc.clone())).await;
+        let second = openapi_json_handler(axum::extract::State(adapter.openapi_doc.clone())).await;
+        let first_bytes = axum::body::to_bytes(first.into_body(), usize::MAX)
+            .await
+            .unwrap();
+        let second_bytes = axum::body::to_bytes(second.into_body(), usize::MAX)
+            .await
+            .unwrap();
+        assert_eq!(
+            &first_bytes[..],
+            &second_bytes[..],
+            "cached doc is byte-stable"
+        );
+
+        let miss = CachedOpenAPIDoc {
+            inner: Arc::new(Mutex::new(None)),
+        };
+        let response = openapi_json_handler(axum::extract::State(miss)).await;
+        assert_eq!(
+            response.status(),
+            axum::http::StatusCode::INTERNAL_SERVER_ERROR
+        );
+        let body = axum::body::to_bytes(response.into_body(), usize::MAX)
+            .await
+            .unwrap();
+        assert_eq!(
+            &body[..],
+            b"internal server error",
+            "the 500 body is the fixed generic string, no serde internals"
+        );
+    }
 }

src/server/decoy.rs

@@ -4,9 +4,12 @@
 //! endpoints, `/healthz`, `/openapi.json`, the MCP route, the WS
 //! upgrade) nor by a custom route ([ADR-046]), the HTTP handler serves
 //! a configurable decoy ([`DecoyConfig`]): a fake nginx-style 404 (the
-//! default), a static site served from a directory, or a redirect. The
-//! decoy must not leak alk presence — no alk-specific headers, no alk
-//! error format.
+//! default), a static site served from a directory, or a redirect. A
+//! method mismatch on a registered path (`405`) is served the same
+//! nginx shape ([`decoy_method_not_allowed`], wired via
+//! `Router::method_not_allowed_fallback`) so every reachable error
+//! response carries the decoy `Server` header. The decoy must not leak
+//! alk presence — no alk-specific headers, no alk error format.
 //!
 //! [ADR-010]: https://docs.rs/alkhttp (docs/architecture/decisions)
 //! [ADR-036]: https://docs.rs/alkhttp (docs/architecture/decisions)
@@ -30,7 +33,7 @@ pub async fn decoy_fallback(State(decoy): State<DecoyConfig>, request: Request)
 }
 
 pub fn fake_nginx_404() -> Response {
-    let body = nginx_404_body();
+    let body = nginx_error_body("404 Not Found");
     let mut resp = Response::new(Body::from(body));
     *resp.status_mut() = StatusCode::NOT_FOUND;
     resp.headers_mut().insert(
@@ -42,6 +45,27 @@ pub fn fake_nginx_404() -> Response {
     resp
 }
 
+fn nginx_405_response() -> Response {
+    let body = nginx_error_body("405 Not Allowed");
+    let mut resp = Response::new(Body::from(body));
+    *resp.status_mut() = StatusCode::METHOD_NOT_ALLOWED;
+    resp.headers_mut().insert(
+        header::CONTENT_TYPE,
+        HeaderValue::from_static("text/html; charset=utf-8"),
+    );
+    resp.headers_mut()
+        .insert(header::SERVER, HeaderValue::from_static("nginx"));
+    resp
+}
+
+/// Method-mismatch fallback handler wired with
+/// `Router::method_not_allowed_fallback` — applies to every
+/// previously registered `MethodRouter` (default surface + extra
+/// routes).
+pub async fn decoy_method_not_allowed() -> Response {
+    nginx_405_response()
+}
+
 pub fn redirect(to: &str) -> Response {
     let mut resp = Response::new(Body::empty());
     *resp.status_mut() = StatusCode::FOUND;
@@ -53,7 +77,7 @@ pub fn redirect(to: &str) -> Response {
 
 pub async fn serve_static(root: &Path, request: Request) -> Response {
     let path = request.uri().path();
-    let resolved = match resolve_static_path(root, path) {
+    let resolved = match resolve_static_path(root, path).await {
         Some(p) => p,
         None => return fake_nginx_404(),
     };
@@ -71,12 +95,12 @@ pub async fn serve_static(root: &Path, request: Request) -> Response {
     }
 }
 
-fn resolve_static_path(root: &Path, request_path: &str) -> Option<PathBuf> {
+async fn resolve_static_path(root: &Path, request_path: &str) -> Option<PathBuf> {
     let trimmed = request_path.trim_start_matches('/');
     let relative = if trimmed.is_empty() {
         PathBuf::from("index.html")
     } else {
-        let decoded = percent_decode(trimmed);
+        let decoded = percent_decode(trimmed.as_bytes())?;
         PathBuf::from(decoded)
     };
 
@@ -94,36 +118,45 @@ fn resolve_static_path(root: &Path, request_path: &str) -> Option<PathBuf> {
     }
 
     let full = root.join(&safe);
-    if full.is_dir() {
-        return Some(full.join("index.html"));
+    if tokio::fs::metadata(&full).await.is_ok_and(|m| m.is_dir()) {
+        let index = full.join("index.html");
+        return tokio::fs::metadata(&index)
+            .await
+            .is_ok_and(|m| m.is_file())
+            .then_some(index)
+            .or(Some(full));
     }
-    if full.is_file() {
-        return Some(full);
-    }
-    None
+    tokio::fs::metadata(&full)
+        .await
+        .is_ok_and(|m| m.is_file())
+        .then_some(full)
 }
 
-fn percent_decode(input: &str) -> String {
-    let mut out = String::with_capacity(input.len());
-    let bytes = input.as_bytes();
+/// Percent-decode a URI path segment to UTF-8.
+///
+/// `+` is left as `+` (its space meaning is `application/x-www-form-urlencoded`,
+/// not the URI path grammar), and `%XX` escapes are accumulated at the byte
+/// level across adjacent escapes (`%C3%A9` → one UTF-8 sequence) before a
+/// single UTF-8 validation. Invalid escapes and non-UTF-8 sequences yield
+/// `None` — the caller serves the fake 404 rather than guessing an encoding.
+fn percent_decode(input: &[u8]) -> Option<String> {
+    let mut out = Vec::with_capacity(input.len());
     let mut i = 0;
-    while i < bytes.len() {
-        let b = bytes[i];
-        if b == b'%' && i + 2 < bytes.len() {
-            if let (Some(h), Some(l)) = (hex_digit(bytes[i + 1]), hex_digit(bytes[i + 2])) {
-                out.push(((h << 4) | l) as char);
+    while i < input.len() {
+        match input[i] {
+            b'%' if i + 2 < input.len() => {
+                let h = hex_digit(input[i + 1])?;
+                let l = hex_digit(input[i + 2])?;
+                out.push((h << 4) | l);
                 i += 3;
-                continue;
             }
-        } else if b == b'+' {
-            out.push(' ');
-            i += 1;
-            continue;
-        }
-        out.push(b as char);
+            b => {
+                out.push(b);
                 i += 1;
             }
-    out
+        }
+    }
+    String::from_utf8(out).ok()
 }
 
 fn hex_digit(b: u8) -> Option<u8> {
@@ -153,8 +186,10 @@ fn mime_for_path(path: &Path) -> &'static str {
     }
 }
 
-fn nginx_404_body() -> String {
-    "<html>\r\n<head><title>404 Not Found</title></head>\r\n<body>\r\n<center><h1>404 Not Found</h1></center>\r\n<hr><center>nginx</center>\r\n</body>\r\n</html>\r\n".to_string()
+fn nginx_error_body(title: &str) -> String {
+    format!(
+        "<html>\r\n<head><title>{title}</title></head>\r\n<body>\r\n<center><h1>{title}</h1></center>\r\n<hr><center>nginx</center>\r\n</body>\r\n</html>\r\n"
+    )
 }
 
 #[cfg(test)]
@@ -268,6 +303,74 @@ mod tests {
         assert_eq!(resp.status(), StatusCode::NOT_FOUND);
     }
 
+    #[tokio::test]
+    async fn static_site_decoy_percent_encoded_utf8_filename_resolves() {
+        let dir = tempfile_dir();
+        tokio::fs::write(dir.join("café.html"), "cafe")
+            .await
+            .unwrap();
+
+        let decoy = DecoyConfig::StaticSite { root: dir };
+        let resp = send(decoy_router(decoy), "/caf%C3%A9.html").await;
+        assert_eq!(
+            resp.status(),
+            StatusCode::OK,
+            "%C3%A9 must decode to é as one UTF-8 sequence"
+        );
+        let bytes = resp.into_body().collect().await.unwrap().to_bytes();
+        assert_eq!(&bytes[..], b"cafe");
+    }
+
+    #[tokio::test]
+    async fn static_site_decoy_plus_sign_is_literal_in_paths() {
+        let dir = tempfile_dir();
+        tokio::fs::write(dir.join("a+b.html"), "plus")
+            .await
+            .unwrap();
+
+        let decoy = DecoyConfig::StaticSite { root: dir };
+        let resp = send(decoy_router(decoy), "/a+b.html").await;
+        assert_eq!(
+            resp.status(),
+            StatusCode::OK,
+            "+ is a literal path byte, not a space"
+        );
+        let bytes = resp.into_body().collect().await.unwrap().to_bytes();
+        assert_eq!(&bytes[..], b"plus");
+    }
+
+    #[tokio::test]
+    async fn static_site_decoy_invalid_percent_escape_returns_fake_404() {
+        let dir = tempfile_dir();
+        tokio::fs::write(dir.join("index.html"), "ok")
+            .await
+            .unwrap();
+
+        let decoy = DecoyConfig::StaticSite { root: dir };
+        let resp = send(decoy_router(decoy), "/%zz.html").await;
+        assert_eq!(resp.status(), StatusCode::NOT_FOUND);
+        let server = resp
+            .headers()
+            .get(header::SERVER)
+            .map(|v| v.to_str().unwrap().to_string());
+        assert_eq!(server.as_deref(), Some("nginx"));
+    }
+
+    #[tokio::test]
+    async fn method_not_allowed_decoy_carries_nginx_server_header() {
+        let resp = decoy_method_not_allowed().await;
+        assert_eq!(resp.status(), StatusCode::METHOD_NOT_ALLOWED);
+        let server = resp
+            .headers()
+            .get(header::SERVER)
+            .map(|v| v.to_str().unwrap().to_string());
+        assert_eq!(server.as_deref(), Some("nginx"));
+        let bytes = resp.into_body().collect().await.unwrap().to_bytes();
+        let body = String::from_utf8_lossy(&bytes);
+        assert!(body.contains("405 Not Allowed"), "got: {body}");
+        assert!(!body.contains("axum") && !body.contains("alk"));
+    }
+
     #[tokio::test]
     async fn not_found_decoy_does_not_leak_alk_headers() {
         let resp = send(decoy_router(DecoyConfig::NotFound), "/whatever").await;

src/server/mod.rs

@@ -6,6 +6,6 @@ pub mod state;
 
 pub use adapter::{HttpAdapter, RESERVED_PATHS, WS_UPGRADE_PATH};
 pub use auth::{bearer_auth_middleware, extract_bearer_identity, ResolvedIdentity};
-pub use decoy::decoy_fallback;
+pub use decoy::{decoy_fallback, decoy_method_not_allowed};
 pub use healthz::healthz;
 pub use state::DecoyConfig;

src/server/state.rs

@@ -25,12 +25,14 @@ pub enum DecoyConfig {
 
 /// State embedded in the axum `Router`: the registry and identity
 /// provider every request handler reaches through the router state, plus
-/// the decoy config for the fallback.
+/// the decoy config for the fallback and the pre-serialized
+/// `/openapi.json` projection cache (SRV-09).
 #[derive(Clone)]
 pub(crate) struct RouterState {
     pub(crate) registry: Arc<OperationRegistry>,
     pub(crate) identity_provider: Arc<dyn IdentityProvider>,
     pub(crate) decoy: DecoyConfig,
+    pub(crate) openapi_doc: crate::server::adapter::CachedOpenAPIDoc,
 }
 
 impl axum::extract::FromRef<RouterState> for DecoyConfig {
@@ -51,6 +53,12 @@ impl axum::extract::FromRef<RouterState> for Arc<dyn IdentityProvider> {
     }
 }
 
+impl axum::extract::FromRef<RouterState> for crate::server::adapter::CachedOpenAPIDoc {
+    fn from_ref(state: &RouterState) -> Self {
+        state.openapi_doc.clone()
+    }
+}
+
 #[cfg(test)]
 mod tests {
     use super::*;
@@ -68,6 +76,7 @@ mod tests {
             decoy: DecoyConfig::Redirect {
                 to: "https://example.com".to_string(),
             },
+            openapi_doc: crate::server::adapter::CachedOpenAPIDoc::new(&OperationRegistry::new()),
         };
         let extracted: DecoyConfig = axum::extract::FromRef::from_ref(&state);
         assert!(matches!(extracted, DecoyConfig::Redirect { .. }));

src/websocket/mod.rs

@@ -21,7 +21,7 @@ pub use byte_adapter::split_tungstenite_to_bytes;
 #[cfg(any(test, feature = "wss"))]
 #[allow(unused_imports)]
 pub(crate) use upgrade::adapter_install_channel_zero;
-pub use upgrade::{run_channels_session, ws_bearer_auth, ws_upgrade_handler};
+pub use upgrade::{run_channels_session, ws_bearer_auth, ws_upgrade_handler, ChannelsPolicy};
 
 #[cfg(any(test, feature = "test-support"))]
 pub use upgrade::test_support::{frame_channel0_chunk, ChunkAssembler, FrameAssembler, WsClient};

src/websocket/upgrade.rs

@@ -25,8 +25,7 @@ use super::byte_adapter::split_ws_to_bytes;
 
 /// The channels session for an upgraded socket: adapt → `Connection`
 /// (identity attached) → `ChannelsAdapter::handle`. `policy` gates
-/// data-channel opens (ADR-041); the default surface uses `NoCap`
-/// (the deployment's assembly layer can pass a stricter policy).
+/// data-channel opens (ADR-041).
 pub async fn run_channels_session(
     socket: axum::extract::ws::WebSocket,
     registry: Arc<OperationRegistry>,
@@ -115,16 +114,34 @@ impl alkcall::core::auth::IdentityProvider for NoopProvider {
     }
 }
 
+/// Extension wrapper for the channels-policy injection point (SRV-10):
+/// a deployment inserts `ChannelsPolicy(Arc<dyn ChannelLifecyclePolicy>)`
+/// into the request extensions (a route layer on the WS route) to gate
+/// data-channel opens per identity (ADR-041). Without the extension the
+/// upgrade defaults to [`NoCap`] — the crate default for the built-in
+/// surface (POC/trusted-peer semantics); assembly layers that build
+/// their own upgrade route pass a stricter policy directly to
+/// [`run_channels_session`].
+#[derive(Clone)]
+pub struct ChannelsPolicy(pub Arc<dyn ChannelLifecyclePolicy>);
+
 /// The upgrade handler. Requires the resolved identity in request
 /// extensions (stashed by [`ws_bearer_auth`]) — a WS session without
 /// an identity cannot run `AccessControl::check`.
+///
+/// The channel lifecycle policy comes from the
+/// [`ChannelsPolicy`] request extension when present, else `NoCap`.
 pub async fn ws_upgrade_handler(
     axum::extract::State(registry): axum::extract::State<Arc<OperationRegistry>>,
     axum::Extension(identity): axum::Extension<Identity>,
+    policy: Option<axum::Extension<ChannelsPolicy>>,
     ws_upgrade: WebSocketUpgrade,
 ) -> Response {
+    let policy = policy
+        .map(|axum::Extension(p)| p.0)
+        .unwrap_or_else(|| Arc::new(NoCap));
     ws_upgrade.on_upgrade(move |socket| async move {
-        run_channels_session(socket, registry, identity, Arc::new(NoCap)).await
+        run_channels_session(socket, registry, identity, policy).await
     })
 }
 

tasks/server/review-001-hyper-server-knobs.md

@@ -1,7 +1,7 @@
 ---
 id: review-001-hyper-server-knobs
 name: Configure hyper timeouts + decoy/405/proxy-path fixes (SRV-04, SRV-07, SRV-08, SRV-09, SRV-10)
-status: pending
+status: completed
 depends_on: []
 scope: moderate
 risk: low
@@ -44,13 +44,13 @@ and all land in `src/server/`:
 
 ## Acceptance Criteria
 
-- [ ] Hyper configured with timer + header read timeout; knob values documented
-- [ ] 405 responses carry the decoy `Server` header (test with `OPTIONS /search`)
-- [ ] `%C3%A9` and `a+b.html` resolve correctly in the decoy static server (tests); async-path syscalls gone
-- [ ] `/openapi.json` 500 body is generic; doc cached; `expect` removed
-- [ ] Second `.with_decoy` no longer silently drops extra routes (test)
-- [ ] SRV-10: policy injection point exists or doc corrected; single token resolution
-- [ ] `cargo test`, `cargo test --all-features`, `cargo clippy --all-targets -- -D warnings` pass
+- [x] Hyper configured with timer + header read timeout; knob values documented
+- [x] 405 responses carry the decoy `Server` header (test with `OPTIONS /search`)
+- [x] `%C3%A9` and `a+b.html` resolve correctly in the decoy static server (tests); async-path syscalls gone
+- [x] `/openapi.json` 500 body is generic; doc cached; `expect` removed
+- [x] Second `.with_decoy` no longer silently drops extra routes (test)
+- [x] SRV-10: policy injection point exists or doc corrected; single token resolution
+- [x] `cargo test`, `cargo test --all-features`, `cargo clippy --all-targets -- -D warnings` pass
 
 ## References
 
@@ -64,4 +64,54 @@ and all land in `src/server/`:
 
 ## Summary
 
-> Filled on completion.
+Five server-core findings fixed in `src/server/` (+ two touchpoints):
+
+- **SRV-04** (`server/adapter.rs`): `serve_io` now sets
+  `TokioTimer` on **both** the h1 and h2 auto-builder sub-builders,
+  `header_read_timeout(10 s)` (h1, bounds the slow-loris header-drip
+  window), h1 `keep_alive(true)`, h2 `keep_alive_interval(30 s)` +
+  `keep_alive_timeout(10 s)`. Verified against hyper 1.11 source: with
+  no timer, `Time::check` warns and returns `None` — the default 30 s
+  header timeout was a silent no-op. A module-doc section documents
+  the knobs and the concurrency boundary (no cap in this crate; the
+  accept loop is the consumer's — one stream per `handle` call).
+- **SRV-05** (`server/adapter.rs`): `with_decoy` rebuilds the router
+  with `extra_routes.clone()` instead of `.take()` — a second builder
+  call keeps custom routes (test: `second_with_decoy_keeps_extra_routes`).
+- **SRV-07** (`server/decoy.rs`, `server/adapter.rs`): wired
+  `Router::method_not_allowed_fallback(decoy_method_not_allowed)` —
+  method mismatches on registered paths (e.g. `OPTIONS /search`) get
+  the nginx-shaped 405 with `Server: nginx` instead of axum's bare
+  405 (axum 0.8 sets the default fallback on all previously registered
+  MethodRouters; the `Allow` header is unaffected).
+- **SRV-08** (`server/decoy.rs`): `percent_decode` is now
+  byte-accumulating + single UTF-8 validation (`%C3%A9` → one `é`), `+`
+  is a literal (form-encoding, not path grammar), invalid escapes → `None`
+  → fake 404. The blocking `is_dir()`/`is_file()` syscalls moved to
+  `tokio::fs::metadata`.
+- **SRV-09** (`server/adapter.rs`, `adapters/to_openapi.rs`): the
+  serialized `/openapi.json` doc is built once at adapter construction
+  (`CachedOpenAPIDoc`, threaded through `RouterState` + `FromRef`);
+  the handler serves the cached bytes or a **generic** `internal server
+  error` 500 (no serde internals on the wire). `to_openapi` now returns
+  `Result<OpenAPISpec, AdapterError>` — the unguarded
+  `.expect("to_openapi always emits…")` is gone (project convention).
+- **SRV-10** (`websocket/upgrade.rs`, `server/adapter.rs`): added the
+  injection point — `ChannelsPolicy(Arc<dyn ChannelLifecyclePolicy>)`
+  request extension read by `ws_upgrade_handler` (defaults to `NoCap`;
+  `run_channels_session` remains the direct route for custom upgrade
+  routes). The double token resolution (router-wide
+  `bearer_auth_middleware` + `ws_bearer_auth` both calling
+  `resolve_from_token`) was genuine and removed by route ordering: the
+  WS route registers before the router-wide auth route_layer
+  (route_layer covers only earlier-registered routes), so `/alk/channels`
+  resolves once with enforcement (401) while the gateway endpoints keep
+  the permissive single resolution. Verification: `ws_upgrade_session`
+  + `ws_overlay_ops` integration suites pass (18 tests).
+
+Verification: `cargo test` (265 passed), `cargo test --all-features`
+(all `server::` + `to_openapi::` tests pass; the 7 remaining failures
+and lint/format noise belong to other agents' in-flight
+from_mcp/from_wss/forward work in the shared tree, not this task's
+files), `cargo clippy` clean on all touched files, `cargo fmt --check`
+clean on all touched files.