Z-A coupling: drop active jog/MDI auto-coordination, keep refuse-only check

The active rewriter for jogs/MDI didn't help anyway because the
continuous-jog buttons send rate-based /api/jog commands to the AVR
and bypass the planner+MDI path entirely. Rather than build out
continuous-jog coupling on the ESP firmware or fake it with browser
ticks, simplify back to:

  * Runtime check (Planner.__encode + ExternalAxis motion entry
    points) refuses any move that would worsen the Z-A gap. Already
    improvement-aware so X/Y jogs and Z-up/A-down recoveries pass.
  * File preprocessor (AuxPreprocessor) injects pre-position A
    moves into uploaded gcode so well-formed programs run without
    operator intervention.

Operator workflow: jog freely down to the safe band; if you need to
go deeper, lower A first (aux jog mm) or use a step-jog MDI like
'G91 G0 Z-10 A-10' that includes the A delta. Programs do the right
thing on their own.

.gitignore

@@ -27,3 +27,19 @@ __pycache__
 *.elf
 *.hex
 .idea/deployment.xml
+backup/*.img.gz
+backup/*.partial
+
+# Demo mode artifacts
+bbctrl.log*
+hooks.json
+/*/bbctrl.log*
+src/py/camotics/__init__.py
+src/py/camotics/gplan.so
+src/avr/emu/bbemu
+src/avr/emu/build/
+
+.pi/pi-python35.tar.gz
+src/py/camotics/gplan.so.built
+tmp/
+backup/

.pi/BUILD.md

@@ -0,0 +1,249 @@
+# Onefinity CNC Firmware — Build, Flash & Backup
+
+## Quick Start
+
+```bash
+# 1. Build gplan.so (first time ~25min, then ~1sec)
+.pi/build-gplan.sh
+
+# 2. Build firmware package (frontend + AVR + Python, ~1min)
+docker run --rm -v "$(pwd):/workspace" -w /workspace onefin-dev \
+  bash -c 'make all && python3 ./setup.py sdist'
+
+# 3. Flash to controller
+curl -X PUT -F "firmware=@dist/bbctrl-1.6.7.tar.bz2" \
+  -F "password=onefinity" http://10.1.10.55/api/firmware/update
+```
+
+## Architecture Overview
+
+The controller is a **Raspberry Pi 2/3** (armv7l, Raspbian Stretch, Python 3.5)
+connected to an **ATxmega192a3u** AVR over serial. The Pi runs a Tornado web
+server that serves the UI, parses G-code, and plans motion. The AVR executes
+realtime step/direction pulses.
+
+```
+Browser ←WebSocket→ Pi (Tornado/Python) → GCode Planner → Serial → AVR → Stepper drivers
+```
+
+The firmware package (`bbctrl-X.Y.Z.tar.bz2`) contains:
+
+| Component | Source | Description |
+|---|---|---|
+| Python backend | `src/py/bbctrl/` | Tornado web server, state machine, planner bridge |
+| Web frontend | `build/http/` | Pug + Stylus + Svelte → static HTML/JS/CSS |
+| AVR firmware | `src/avr/bbctrl-avr-firmware.hex` | Realtime motion controller |
+| gplan.so | `src/py/camotics/gplan.so` | CAMotics G-code planner (native ARM C++ extension) |
+| Install scripts | `scripts/install.sh` | AVR flash, Python install, service restart |
+
+## Prerequisites
+
+- **Docker** with QEMU binfmt support (default on Docker Desktop for Mac)
+- **devcontainer image**: `docker build -t onefin-dev -f .devcontainer/Dockerfile .devcontainer/`
+- **SSH access**: `ssh bbmc@10.1.10.55` (password: `onefinity`)
+
+## Building
+
+### Step 1: gplan.so
+
+`gplan.so` is the CAMotics G-code planner — a C++ Python extension that must
+be a **32-bit ARM binary linked against Python 3.5**. It cannot be built in the
+devcontainer (wrong arch + wrong Python + wrong glibc).
+
+**Build from source** (recommended):
+
+```bash
+.pi/build-gplan.sh
+```
+
+This uses a Raspbian Stretch Docker image (`balenalib/raspberry-pi-debian:stretch`)
+with the Pi's exact toolchain: GCC 6.3, Python 3.5, GLIBC 2.24. The image is
+built once (~25min under QEMU), then cached — subsequent runs take ~1sec.
+
+The image pre-compiles two C++ dependencies:
+- [cbang](https://github.com/CauldronDevelopmentLLC/cbang) @ `18f1e96` — C++ utility library
+- [camotics](https://github.com/CauldronDevelopmentLLC/camotics) @ `ec876c8` — G-code planner with S-curve motion planning
+
+To force a full rebuild: `docker rmi onefin-gplan && .pi/build-gplan.sh`
+
+**Alternatives** (if Docker build fails):
+
+```bash
+# From official release
+curl -sL https://github.com/OneFinityCNC/onefinity-firmware/releases/download/v1.6.6/onefinity-1.6.6.tar.bz2 \
+  | tar xjf - --include='*/gplan.so' -O > src/py/camotics/gplan.so
+
+# From the running Pi
+scp bbmc@10.1.10.55:/usr/local/lib/python3.5/dist-packages/bbctrl-*.egg/camotics/gplan.so src/py/camotics/
+```
+
+**Verify** — must show `ELF 32-bit ... ARM ... libpython3.5m`:
+
+```bash
+file src/py/camotics/gplan.so
+readelf -d src/py/camotics/gplan.so | grep python
+```
+
+### Step 2: Firmware package
+
+```bash
+docker run --rm -v "$(pwd):/workspace" -w /workspace onefin-dev \
+  bash -c 'make all && python3 ./setup.py sdist'
+```
+
+This builds inside the devcontainer (arm64 Bullseye — fine for frontend/AVR/Python):
+
+| Component | Tool | Time |
+|---|---|---|
+| Node modules | `npm install` | ~30sec |
+| Svelte components | `vite build` | ~5sec |
+| Pug/Stylus → HTML | `pug-cli`, `stylus` | ~2sec |
+| AVR firmware | `avr-g++` (ATxmega192a3u) | ~10sec |
+| Boot/Power/Jig MCUs | `avr-gcc` | ~5sec |
+| Python sdist | `setup.py sdist` | ~2sec |
+
+Produces: `dist/bbctrl-X.Y.Z.tar.bz2` (~3-4MB)
+
+### bbserial.ko (kernel module — usually skip)
+
+Cross-compiles against the Pi's kernel headers (4.9.59-v7+). The Pi already has
+a working `bbserial.ko` installed. `install.sh` skips it gracefully if missing.
+
+## Flashing
+
+### Via web API (machine running)
+
+```bash
+curl -X PUT -F "firmware=@dist/bbctrl-1.6.7.tar.bz2" \
+  -F "password=onefinity" http://10.1.10.55/api/firmware/update
+```
+
+Or: `make update HOST=10.1.10.55`
+
+### Via SSH (web UI down or crash-looping)
+
+```bash
+scp dist/bbctrl-1.6.7.tar.bz2 bbmc@10.1.10.55:/tmp/
+ssh bbmc@10.1.10.55 'echo onefinity | sudo -S bash -c "
+  systemctl stop bbctrl
+  mkdir -p /var/lib/bbctrl/firmware
+  cp /tmp/bbctrl-1.6.7.tar.bz2 /var/lib/bbctrl/firmware/update.tar.bz2
+  /usr/local/bin/update-bbctrl
+"'
+```
+
+### What happens during flash
+
+1. `update-bbctrl` stops bbctrl, extracts tarball to `/tmp/update/`
+2. `install.sh` runs:
+   - Flashes AVR via `scripts/avr109-flash.py` (serial bootloader protocol)
+   - `setup.py install --force` — installs Python package + frontend + gplan.so
+   - Restarts `bbctrl` systemd service
+   - May reboot if boot config or kernel module changed
+
+### Recovery from bad flash
+
+SSH still works even when bbctrl is crash-looping:
+1. Check the error: `sudo python3 /usr/local/bin/bbctrl 2>&1 | head -20`
+2. Common cause: wrong gplan.so architecture → replace with correct one (see above)
+3. Nuclear option: restore SD card from backup
+
+## Running Locally (demo mode)
+
+Full stack in Docker with AVR emulator — no Pi needed:
+
+```bash
+# Build bbemu (AVR emulator, native in devcontainer)
+docker run --rm -v "$(pwd):/workspace" -w /workspace/src/avr/emu onefin-dev make
+
+# Run demo (needs arm64 gplan.so for the container, not armhf)
+docker run --rm -d --name onefin-demo \
+  -v "$(pwd):/workspace" -w /workspace -p 8765:80 \
+  onefin-dev bash -c '
+    pip3 install -q tornado sockjs-tornado pyserial watchdog
+    cp src/avr/emu/bbemu /usr/local/bin/
+    pip3 install -q -e .
+    exec bbctrl --demo --port 80 --addr 0.0.0.0 --disable-camera
+  '
+```
+
+Open http://localhost:8765 — full UI with emulated controller.
+
+Note: demo mode needs a **container-arch** gplan.so (arm64 + Python 3.9), not the
+Pi one. The devcontainer build from the Makefile's `gplan` target produces this,
+or it can be built following the procedure in `scripts/gplan-build.sh`.
+
+## SD Card Backup & Restore
+
+```bash
+# Backup (~50 min, streams raw dd from Pi, compresses locally)
+./backup/onefinity-backup.sh backup
+
+# Verify
+./backup/onefinity-backup.sh verify backup/onefinity-20260430.img.gz
+
+# Restore to local SD card
+./backup/onefinity-backup.sh restore backup/onefinity-20260430.img.gz /dev/diskN
+
+# Restore back to Pi over SSH
+./backup/onefinity-backup.sh restore backup/onefinity-20260430.img.gz
+```
+
+Environment: `ONEFINITY_HOST` (default 10.1.10.55), `ONEFINITY_USER` (bbmc),
+`ONEFINITY_PASS` (onefinity).
+
+## Python 3.5 Compatibility
+
+The Pi runs Python 3.5.3. Avoid features added in later versions:
+
+| Avoid | Use instead |
+|---|---|
+| `f"hello {name}"` | `"hello %s" % name` or `"hello {}".format(name)` |
+| `subprocess.run(capture_output=True)` | `stdout=subprocess.PIPE, stderr=subprocess.PIPE` |
+| `subprocess.run(text=True)` | `.stdout.decode('utf-8')` |
+| `dataclasses` | plain classes with `__init__` |
+| `:=` walrus operator | separate assignment |
+| `asyncio.run()` | `loop.run_until_complete()` |
+| `dict[str, int]` | `Dict[str, int]` from `typing` |
+
+## Pi Details
+
+| | |
+|---|---|
+| Host | `10.1.10.55` |
+| SSH | `bbmc` / `onefinity` |
+| OS | Raspbian Stretch (Debian 9) |
+| Kernel | 4.9.59-v7+ |
+| Python | 3.5.3 |
+| GCC | 6.3.0 |
+| GLIBC | 2.24 (max symbol: GLIBC_2.24) |
+| GLIBCXX | 3.4.22 |
+| Arch | armv7l (32-bit ARM, EABI5) |
+| SD card | 30GB (~2.8GB used) |
+| Service | `systemctl {start,stop,restart,status} bbctrl` |
+| Log | `/var/log/bbctrl.log` or `journalctl -u bbctrl` |
+| Config | `/var/lib/bbctrl/config.json` |
+| Uploads | `/var/lib/bbctrl/upload/` |
+| Web root | `/usr/local/lib/python3.5/dist-packages/bbctrl-*.egg/bbctrl/http/` |
+| AVR serial | `/dev/ttyAMA0` at 230400 baud |
+
+## Why Not Build gplan.so on Bullseye?
+
+Documented for reference — we tried two approaches that don't work:
+
+**1. devcontainer (arm64 Bullseye):** Wrong ELF class (64-bit vs 32-bit) and wrong
+Python (3.9 vs 3.5). Cross-compiling with `CXX=arm-linux-gnueabihf-g++` fails
+because SCons ignores CC/CXX environment variables.
+
+**2. Bullseye armhf container:** Correct architecture, but GCC 10 / glibc 2.31
+produce objects requiring GLIBC_2.29+ and GLIBCXX_3.4.26+ symbols. The Pi's
+Stretch only has GLIBC_2.24 / GLIBCXX_3.4.22. Even `-static-libstdc++
+-static-libgcc` doesn't help — glibc symbols leak through the object files.
+Relinking against Python 3.5m works but the GLIBC mismatch remains.
+
+**3. Plain `debian:stretch` armhf:** The archived repos have broken package
+metadata — `apt-get install build-essential` fails with unresolvable version
+conflicts.
+
+**Solution:** `balenalib/raspberry-pi-debian:stretch` with `legacy.raspbian.org`
+repos. See `.pi/Dockerfile.gplan`.

.pi/Dockerfile.gplan

@@ -0,0 +1,48 @@
+# Raspbian Stretch armhf build environment for gplan.so
+# Matches the Pi exactly: GCC 6.3, Python 3.5, GLIBC 2.24
+#
+# Build image:  docker build -t onefin-gplan -f .pi/Dockerfile.gplan .pi/
+# Build gplan:  .pi/build-gplan.sh
+FROM balenalib/raspberry-pi-debian:stretch
+
+# Fix repos to use archived Raspbian mirrors
+RUN echo "deb http://legacy.raspbian.org/raspbian/ stretch main contrib non-free rpi" \
+      > /etc/apt/sources.list && \
+    rm -f /etc/apt/sources.list.d/*.list
+
+RUN apt-get -o Acquire::Check-Valid-Until=false \
+      -o Acquire::AllowInsecureRepositories=true update && \
+    apt-get -o Acquire::Check-Valid-Until=false --allow-unauthenticated \
+      install -y --no-install-recommends \
+      build-essential python3-dev scons git ca-certificates \
+      libssl-dev libexpat1-dev libbz2-dev liblz4-dev zlib1g-dev perl file && \
+    rm -rf /var/lib/apt/lists/*
+
+# Clone and build cbang
+RUN mkdir -p /opt/cbang && cd /opt/cbang && git init -q && \
+    git remote add origin https://github.com/CauldronDevelopmentLLC/cbang && \
+    git fetch --depth 1 -q origin 18f1e963107ef26abe750c023355a5c40dd07853 && \
+    git reset --hard FETCH_HEAD -q && \
+    scons -j2 disable_local="re2 libevent" && \
+    rm -rf .git build/dep
+
+# Clone, patch, and build camotics/gplan
+RUN mkdir -p /opt/camotics && cd /opt/camotics && git init -q && \
+    git remote add origin https://github.com/CauldronDevelopmentLLC/camotics && \
+    git fetch --depth 1 -q origin ec876c80d20fc19837133087cef0c447df5a939d && \
+    git reset --hard FETCH_HEAD -q && \
+    mkdir -p build && touch build/version.txt && \
+    P="src/gcode/plan" && \
+    for F in LineCommand.cpp LinePlanner.cpp; do \
+      for V in maxVel maxJerk maxAccel; do \
+        perl -i -0pe "s/(fabs\((config\.$V\[axis\]) \/ unit\[axis\]\));/std::min(\2, \1);/gm" $P/$F; \
+      done; \
+    done && \
+    rm -rf .git
+
+ENV CBANG_HOME=/opt/cbang
+
+# Pre-compile everything including gplan.so
+RUN cd /opt/camotics && scons -j2 gplan.so with_gui=0 with_tpl=0
+
+WORKDIR /opt/camotics

.pi/build-gplan.sh

@@ -0,0 +1,30 @@
+#!/usr/bin/env bash
+set -euo pipefail
+
+# Build gplan.so for the Onefinity Pi (armv7l, Python 3.5, GCC 6.3)
+#
+# Uses a Raspbian Stretch Docker image that exactly matches the Pi's
+# toolchain. No cross-compile, no relink hacks, no GLIBC mismatches.
+#
+# First run:   ~30min  (builds Docker image with cbang + camotics)
+# After that:  ~1sec   (copies pre-built gplan.so from image)
+
+SCRIPT_DIR="$(cd "$(dirname "$0")" && pwd)"
+PROJECT_DIR="$(dirname "$SCRIPT_DIR")"
+IMAGE="onefin-gplan"
+OUTPUT="$PROJECT_DIR/src/py/camotics/gplan.so"
+
+# Build image if needed (one-time)
+if ! docker image inspect "$IMAGE" >/dev/null 2>&1; then
+    echo "Building $IMAGE Docker image (one-time, ~30min under QEMU)..."
+    docker build -t "$IMAGE" -f "$SCRIPT_DIR/Dockerfile.gplan" "$SCRIPT_DIR"
+fi
+
+# Copy gplan.so out of the image
+echo "Extracting gplan.so..."
+docker run --rm -v "$PROJECT_DIR:/workspace" "$IMAGE" \
+    bash -c 'cp /opt/camotics/gplan.so /workspace/src/py/camotics/gplan.so && \
+             file /workspace/src/py/camotics/gplan.so && \
+             readelf -d /workspace/src/py/camotics/gplan.so | grep -E "NEEDED|python"'
+
+echo "✓ Built: $OUTPUT"

Makefile

@@ -68,7 +68,11 @@ update: pkg
 
 build/templates.pug: $(TEMPLS)
 	mkdir -p build
-	cat $(TEMPLS) >$@
+	# Use awk to ensure each template is followed by a newline so the
+	# next file's first line never gets glued onto the previous file's
+	# last line (some templates ship without a trailing newline, which
+	# would produce subtle Pug parse failures).
+	awk 'FNR==1 && NR>1 {print ""} {print} END{print ""}' $(TEMPLS) >$@
 
 node_modules: package.json
 	npm install && touch node_modules

README.md

@@ -1 +1,122 @@
-#OneFinity CNC Controller Firmware
+# OneFinity CNC Controller Firmware (W-axis fork)
+
+This is the OneFinity / Buildbotics bbctrl firmware with a virtual W
+axis driven by an auxcnc ESP32 over USB serial. See
+[docs/AUX_W_AXIS.md](docs/AUX_W_AXIS.md) for the design and config.
+
+## Layout
+
+```
+src/avr/        AVR firmware (motion controller, AtxMega)
+src/boot/       AVR bootloader
+src/bbserial/   Linux kernel module for the bbserial driver
+src/py/bbctrl/  Python control daemon (Tornado + websockets)
+src/js/         Vue.js UI (legacy)
+src/svelte-components/  Newer Svelte UI for dialogs and settings
+src/pug/        Pug templates compiled into build/http/index.html
+src/resources/  Static assets and config templates
+scripts/        Install / update / RPi build helpers
+docs/           Architecture, dev setup, W-axis docs
+```
+
+## Build & flash (quick path, macOS or Linux)
+
+The full build (`make`) requires `avr-gcc`, but the controller and UI
+only depend on the Python + web parts. If you're shipping a UI/Python
+change you don't need the AVR toolchain.
+
+### Prerequisites
+
+- Node.js (any recent LTS) with npm
+- Python 3 with setuptools
+- `npm install` once at the project root (this is wired into the
+  `node_modules` Make target, but on a fresh checkout it's clearer to
+  do it explicitly)
+
+```bash
+npm install
+(cd src/svelte-components && npm install)
+```
+
+#### macOS gotcha: esbuild platform pin
+
+The Pi build leaves `node_modules/esbuild` pinned to
+`linux-arm64`, which won't run on Darwin. If `npm run build` inside
+`src/svelte-components` complains about esbuild, reinstall it for the
+host:
+
+```bash
+cd src/svelte-components
+rm -rf node_modules/esbuild
+npm install esbuild@0.14.49 --no-save
+```
+
+(Use the version that matches `package-lock.json`.)
+
+### Build the web UI + Python sdist
+
+```bash
+# Build the Svelte components
+(cd src/svelte-components && npm run build)
+
+# Render pug templates and copy assets into build/http
+make all          # AVR step will fail without avr-gcc; safe to ignore
+                  # if you didn't change anything under src/avr or src/boot
+
+# Package
+./setup.py sdist
+ls dist/bbctrl-*.tar.bz2
+```
+
+`make pkg` is the canonical target but it tries to build AVR first. On
+hosts without avr-gcc, run the steps above directly.
+
+If `bbctrl-*.tar.bz2` is missing `src/bbserial/bbserial.ko`, copy the
+prebuilt `.ko` from a previous official release into `src/bbserial/`
+before running `setup.py sdist` (the install script on the controller
+just installs the existing module if a newer one isn't shipped).
+
+### Flash to a controller
+
+```bash
+curl -X PUT -H "Content-Type: multipart/form-data" \
+  -F "firmware=@dist/bbctrl-1.6.7.tar.bz2" \
+  -F "password=onefinity" \
+  http://onefinity.local/api/firmware/update
+```
+
+…or use the Make target:
+
+```bash
+make update HOST=onefinity.local PASSWORD=onefinity
+```
+
+The controller stops bbctrl, untars the package, runs
+`scripts/install.sh`, and brings the service back up. Total downtime
+is ~30-45s. Watch progress at `http://<host>/` (you'll get 404s while
+bbctrl restarts, then the new UI).
+
+### Verify the flash
+
+```bash
+curl -s http://onefinity.local/ | grep -c "OneFinity"
+curl -s http://onefinity.local/api/aux/status   # if W axis is enabled
+```
+
+## Build & flash (full path, Debian/Linux)
+
+For AVR + GPlan rebuilds, see [docs/development.md](docs/development.md).
+That path uses qemu + chroot to cross-compile gplan for ARM and needs
+the `gcc-avr` / `avr-libc` toolchain.
+
+## W axis (auxcnc)
+
+This fork adds a virtual W axis. See
+[docs/AUX_W_AXIS.md](docs/AUX_W_AXIS.md) for:
+
+- G-code surface (`G28 W0`, `G1 W25`, etc.)
+- The G-code preprocessor and hook architecture
+- aux.json keys
+- REST API (`/api/aux/*`)
+- UI surface (jog row in Control, settings panel in Settings)
+- Edge cases (ESP reboot mid-job, limit closed at home start, …)

backup/onefinity-backup.sh

@@ -0,0 +1,278 @@
+#!/usr/bin/env bash
+set -euo pipefail
+
+# Onefinity CNC Controller - SD Card Backup & Restore
+#
+# Backs up the Raspberry Pi's SD card over SSH as a compressed image.
+# Compression runs on the local machine (fast), raw bytes stream from the Pi.
+#
+# Usage:
+#   ./onefinity-backup.sh backup              # backup with defaults
+#   ./onefinity-backup.sh backup -o myfile.gz  # custom output file
+#   ./onefinity-backup.sh restore image.gz     # restore to SD card
+#   ./onefinity-backup.sh verify image.gz      # verify image integrity
+#
+# Environment:
+#   ONEFINITY_HOST  - Pi IP/hostname    (default: 10.1.10.55)
+#   ONEFINITY_USER  - SSH user          (default: bbmc)
+#   ONEFINITY_PASS  - sudo password     (default: onefinity)
+
+HOST="${ONEFINITY_HOST:-10.1.10.55}"
+USER="${ONEFINITY_USER:-bbmc}"
+PASS="${ONEFINITY_PASS:-onefinity}"
+BACKUP_DIR="$(cd "$(dirname "$0")" && pwd)"
+DEVICE="/dev/mmcblk0"
+
+ssh_cmd() {
+    ssh -o ConnectTimeout=10 -o StrictHostKeyChecking=no -o LogLevel=ERROR "$USER@$HOST" "$@"
+}
+
+sudo_ssh() {
+    ssh_cmd "echo '$PASS' | sudo -S bash -c '$1' 2>/dev/null"
+}
+
+die() { echo "ERROR: $*" >&2; exit 1; }
+
+# ── Backup ──────────────────────────────────────────────────────────────────
+
+do_backup() {
+    local outfile=""
+
+    while [[ $# -gt 0 ]]; do
+        case "$1" in
+            -o|--output) outfile="$2"; shift 2 ;;
+            *) die "Unknown option: $1" ;;
+        esac
+    done
+
+    if [[ -z "$outfile" ]]; then
+        outfile="$BACKUP_DIR/onefinity-$(date +%Y%m%d-%H%M).img.gz"
+    fi
+
+    echo "╔══════════════════════════════════════════════════════╗"
+    echo "║  Onefinity CNC Controller - SD Card Backup          ║"
+    echo "╚══════════════════════════════════════════════════════╝"
+    echo ""
+    echo "  Host:   $USER@$HOST"
+    echo "  Device: $DEVICE"
+    echo "  Output: $outfile"
+    echo ""
+
+    # Check connectivity
+    echo "→ Checking SSH connection..."
+    ssh_cmd 'hostname' >/dev/null 2>&1 || die "Cannot SSH to $USER@$HOST"
+
+    # Get card size
+    local card_bytes
+    card_bytes=$(sudo_ssh "blockdev --getsize64 $DEVICE")
+    local card_gb=$(echo "scale=1; $card_bytes / 1073741824" | bc)
+    echo "  SD card: ${card_gb}GB ($card_bytes bytes)"
+    echo ""
+
+    # Check for enough local disk space (compressed is ~4% of raw)
+    local avail_bytes
+    avail_bytes=$(df -P "$(dirname "$outfile")" | tail -1 | awk '{print $4 * 1024}')
+    local need_bytes=$((card_bytes / 10))  # conservative: assume 10% compressed
+    if (( avail_bytes < need_bytes )); then
+        die "Not enough local disk space. Need ~$(echo "scale=1; $need_bytes/1073741824" | bc)GB, have $(echo "scale=1; $avail_bytes/1073741824" | bc)GB"
+    fi
+
+    # Stream raw dd from Pi, compress locally with gzip
+    # The Pi's SD card reads at ~20MB/s which is the bottleneck.
+    # Compressing locally on a fast machine is much better than on the ARM.
+    echo "→ Streaming SD card image (this takes ~20-50 minutes)..."
+    echo "  Pi: dd → SSH → local gzip → $outfile"
+    echo ""
+
+    local start_time=$SECONDS
+    local tmpfile="${outfile}.partial"
+
+    ssh_cmd "echo '$PASS' | sudo -S dd if=$DEVICE bs=4M 2>/dev/null" 2>/dev/null \
+        | gzip -1 > "$tmpfile" &
+    local pid=$!
+
+    # Progress monitor
+    while kill -0 $pid 2>/dev/null; do
+        sleep 15
+        if [[ -f "$tmpfile" ]]; then
+            local size_h
+            size_h=$(ls -lh "$tmpfile" 2>/dev/null | awk '{print $5}')
+            local elapsed=$(( SECONDS - start_time ))
+            local min=$(( elapsed / 60 ))
+            local sec=$(( elapsed % 60 ))
+            printf "\r  %dm%02ds elapsed — %s compressed" "$min" "$sec" "$size_h"
+        fi
+    done
+
+    wait $pid
+    local exit_code=$?
+    echo ""
+
+    if [[ $exit_code -ne 0 ]]; then
+        rm -f "$tmpfile"
+        die "Backup failed (exit code $exit_code)"
+    fi
+
+    mv "$tmpfile" "$outfile"
+
+    local elapsed=$(( SECONDS - start_time ))
+    local final_size
+    final_size=$(ls -lh "$outfile" | awk '{print $5}')
+
+    echo ""
+    echo "→ Verifying image integrity..."
+    if gzip -t "$outfile" 2>/dev/null; then
+        echo "  ✓ gzip integrity OK"
+    else
+        die "Image file is corrupt!"
+    fi
+
+    # Verify full size by counting decompressed bytes
+    local actual_bytes
+    actual_bytes=$(gzip -d -c "$outfile" | wc -c | tr -d ' ')
+    if [[ "$actual_bytes" -eq "$card_bytes" ]]; then
+        echo "  ✓ Size matches: $actual_bytes bytes (full ${card_gb}GB card)"
+    else
+        echo "  ⚠ Size mismatch: expected $card_bytes, got $actual_bytes"
+    fi
+
+    echo ""
+    echo "╔══════════════════════════════════════════════════════╗"
+    echo "  ✓ Backup complete"
+    echo "  File: $outfile"
+    echo "  Size: $final_size compressed (${card_gb}GB raw)"
+    echo "  Time: $(( elapsed / 60 ))m $(( elapsed % 60 ))s"
+    echo "╚══════════════════════════════════════════════════════╝"
+}
+
+# ── Restore ─────────────────────────────────────────────────────────────────
+
+do_restore() {
+    local imgfile="$1"
+    local target="${2:-}"
+
+    [[ -f "$imgfile" ]] || die "Image file not found: $imgfile"
+
+    echo "╔══════════════════════════════════════════════════════╗"
+    echo "║  Onefinity CNC Controller - SD Card Restore         ║"
+    echo "╚══════════════════════════════════════════════════════╝"
+    echo ""
+
+    if [[ -n "$target" ]]; then
+        # ── Local restore: write to a local SD card device ──
+        [[ -b "$target" ]] || die "$target is not a block device"
+
+        local target_bytes
+        target_bytes=$(diskutil info -plist "$target" 2>/dev/null \
+            | plutil -extract TotalSize raw - 2>/dev/null \
+            || blockdev --getsize64 "$target" 2>/dev/null \
+            || echo 0)
+
+        echo "  Image:  $imgfile"
+        echo "  Target: $target ($(echo "scale=1; $target_bytes/1073741824" | bc)GB)"
+        echo ""
+        echo "  ⚠  THIS WILL ERASE ALL DATA ON $target"
+        echo ""
+        read -rp "  Type YES to continue: " confirm
+        [[ "$confirm" == "YES" ]] || die "Aborted"
+
+        echo ""
+        echo "→ Unmounting target..."
+        diskutil unmountDisk "$target" 2>/dev/null || true
+
+        echo "→ Writing image to $target..."
+        local raw_target
+        raw_target=$(echo "$target" | sed 's|/dev/disk|/dev/rdisk|')
+        gzip -d -c "$imgfile" | sudo dd of="$raw_target" bs=4M status=progress
+        sync
+
+        echo ""
+        echo "  ✓ Restore complete. Safe to eject $target."
+
+    else
+        # ── Remote restore: write back to Pi over SSH ──
+        echo "  Image:  $imgfile"
+        echo "  Target: $USER@$HOST:$DEVICE"
+        echo ""
+        echo "  ⚠  THIS WILL ERASE THE PI'S SD CARD"
+        echo "  ⚠  The Pi must be booted from USB/network, not the SD card"
+        echo ""
+        read -rp "  Type YES to continue: " confirm
+        [[ "$confirm" == "YES" ]] || die "Aborted"
+
+        echo ""
+        echo "→ Writing image to $HOST:$DEVICE..."
+        gzip -d -c "$imgfile" \
+            | ssh_cmd "echo '$PASS' | sudo -S dd of=$DEVICE bs=4M 2>/dev/null"
+
+        echo ""
+        echo "  ✓ Remote restore complete."
+    fi
+}
+
+# ── Verify ──────────────────────────────────────────────────────────────────
+
+do_verify() {
+    local imgfile="$1"
+    [[ -f "$imgfile" ]] || die "Image file not found: $imgfile"
+
+    echo "Verifying: $imgfile"
+    echo ""
+
+    local compressed_size
+    compressed_size=$(ls -lh "$imgfile" | awk '{print $5}')
+    echo "  Compressed size: $compressed_size"
+
+    echo "  Checking gzip integrity..."
+    if gzip -t "$imgfile" 2>/dev/null; then
+        echo "  ✓ gzip OK"
+    else
+        die "gzip integrity check FAILED"
+    fi
+
+    echo "  Counting uncompressed bytes..."
+    local raw_bytes
+    raw_bytes=$(gzip -d -c "$imgfile" | wc -c | tr -d ' ')
+    local raw_gb=$(echo "scale=1; $raw_bytes / 1073741824" | bc)
+    echo "  ✓ Uncompressed size: ${raw_gb}GB ($raw_bytes bytes)"
+
+    echo "  Checking partition table..."
+    gzip -d -c "$imgfile" 2>/dev/null | head -c 512 | xxd | head -4 || true
+
+    echo ""
+    echo "  ✓ Image looks valid"
+}
+
+# ── Main ────────────────────────────────────────────────────────────────────
+
+usage() {
+    cat <<EOF
+Usage: $(basename "$0") <command> [options]
+
+Commands:
+  backup  [-o file.img.gz]           Backup SD card from Pi over SSH
+  restore <image.gz> [/dev/diskN]    Restore image to local SD card or remote Pi
+  verify  <image.gz>                 Verify image integrity
+
+Environment variables:
+  ONEFINITY_HOST  Pi address    (default: 10.1.10.55)
+  ONEFINITY_USER  SSH user      (default: bbmc)
+  ONEFINITY_PASS  sudo password (default: onefinity)
+
+Examples:
+  $(basename "$0") backup
+  $(basename "$0") backup -o /tmp/mybackup.img.gz
+  $(basename "$0") restore backup/onefinity-20260430.img.gz /dev/disk4
+  $(basename "$0") verify backup/onefinity-20260430.img.gz
+EOF
+    exit 1
+}
+
+[[ $# -ge 1 ]] || usage
+
+case "$1" in
+    backup)  shift; do_backup "$@" ;;
+    restore) shift; [[ $# -ge 1 ]] || usage; do_restore "$@" ;;
+    verify)  shift; [[ $# -ge 1 ]] || usage; do_verify "$@" ;;
+    *)       usage ;;
+esac

deploy-hardware.sh

@@ -0,0 +1,4 @@
+#!/bin/bash
+# Shorthand for ./deploy.sh hardware
+SCRIPT_DIR="$(cd "$(dirname "${BASH_SOURCE[0]}")" && pwd)"
+exec "$SCRIPT_DIR/deploy.sh" hardware "$@"

deploy-local.sh

@@ -0,0 +1,4 @@
+#!/bin/bash
+# Shorthand for ./deploy.sh local
+SCRIPT_DIR="$(cd "$(dirname "${BASH_SOURCE[0]}")" && pwd)"
+exec "$SCRIPT_DIR/deploy.sh" local "$@"

deploy-prod.sh

@@ -0,0 +1,4 @@
+#!/bin/bash
+# Shorthand for ./deploy.sh prod
+SCRIPT_DIR="$(cd "$(dirname "${BASH_SOURCE[0]}")" && pwd)"
+exec "$SCRIPT_DIR/deploy.sh" prod "$@"

deploy.sh

@@ -0,0 +1,52 @@
+#!/bin/bash
+# Onefinity firmware deploy script.
+#
+#   ./deploy.sh local            — build & static-serve the UI on macOS
+#                                   (chrome only; no controller, shows
+#                                   DISCONNECTED overlay)
+#   ./deploy.sh hardware         — fast iteration: rsync build/http/
+#                                   contents to the running Pi at
+#                                   onefinity.local, then restart bbctrl
+#   ./deploy.sh prod             — full firmware update via the Pi's
+#                                   /api/firmware/update endpoint
+#                                   (equivalent to `make update`)
+#
+# Notes:
+#   * On macOS we cannot run the Python `bbctrl` controller directly
+#     because it imports the ARM-only camotics gplan.so. For full UI
+#     testing with live data, deploy to the Pi (hardware or prod).
+#   * `prod` requires a clean working tree.
+
+set -euo pipefail
+
+SCRIPT_DIR="$(cd "$(dirname "${BASH_SOURCE[0]}")" && pwd)"
+cd "$SCRIPT_DIR"
+
+CMD="${1:-}"
+
+case "$CMD" in
+  local)    exec "$SCRIPT_DIR/scripts/deploy/local.sh" "$@" ;;
+  hardware) exec "$SCRIPT_DIR/scripts/deploy/hardware.sh" "$@" ;;
+  prod)     exec "$SCRIPT_DIR/scripts/deploy/prod.sh" "$@" ;;
+  *)
+    cat <<USAGE
+usage: $0 {local | hardware | prod}
+
+  local     Build the UI and static-serve build/http/ in a tmux session
+            on macOS. Useful for iterating on the V09 chrome and routing.
+            URL: http://localhost:8770/
+            tmux: tmux attach -t onefin-local
+
+  hardware  Fast iteration on the actual controller: rsync the freshly
+            built build/http/ tree onto onefinity.local, then restart
+            the bbctrl service. Requires SSH access as bbmc@onefinity.local.
+            Defaults: HOST=onefinity.local PASSWORD=onefinity
+
+  prod      Build a full firmware package (.tar.bz2) and PUT it through
+            /api/firmware/update on the Pi. Equivalent to:
+              make update HOST=onefinity.local PASSWORD=onefinity
+            Requires a clean working tree.
+USAGE
+    exit 1
+    ;;
+esac

docs/AUX_W_AXIS.md

@@ -0,0 +1,172 @@
+# W axis (auxcnc) integration
+
+This adds a virtual `W` axis to the bbctrl controller, driven by the
+auxcnc ESP32 over USB serial (`/dev/ttyUSB0`). The ESP owns step-pulse
+generation, real-time limit-switch monitoring, and the homing dance.
+The Pi owns units (mm), soft limits, sequencing inside G-code jobs, and
+a small REST API for jogging / homing from the UI.
+
+## How it works
+
+The bbctrl planner (gplan) only understands `xyzabc`, so adding a true
+7th axis would require rebuilding gplan + the AVR firmware. We avoid
+that by treating W as a synchronous out-of-band axis: W moves run
+*between* G-code blocks, not blended with XYZ.
+
+Pipeline:
+
+1. User uploads a G-code file containing `W` words.
+2. `FileHandler` runs `AuxPreprocessor` on the upload, rewriting W
+   tokens in place into `(MSG,HOOK:aux:<mm>)` etc. The original line
+   minus the W word continues to drive XYZ.
+3. The planner sees only XYZ + message comments. When it reaches a
+   message line, the message goes through `state.add_message` which
+   `Hooks._on_state_change` watches for the `HOOK:` prefix.
+4. `Hooks._fire('custom', ...)` finds the registered internal handler
+   for the event name (`aux`, `aux_rel`, `aux_home`, `aux_setzero`).
+5. The handler runs in a hook thread, gating `Mach.unpause` until done.
+   While the handler is busy the machine is in HOLDING - no XYZ motion
+   can resume until W finishes.
+6. The handler talks to the ESP over `/dev/ttyUSB0` via `AuxAxis`,
+   blocking on a deterministic reply token (`[step] done`, `[home]
+   done`, etc).
+
+MDI commands containing `W` words are rewritten the same way at the
+`Mach.mdi()` boundary so manual jog and macros work too.
+
+## G-code surface
+
+```gcode
+G21 G90
+G28 W0          ; home W axis
+G1 W25 F300     ; move W to 25 mm absolute
+G1 X100 W12.5   ; mixed: W moves first, then XYZ (configurable)
+G91
+G1 W-2.5        ; relative W move
+G90
+G92 W0          ; set current W as zero (G92-style)
+```
+
+Rules:
+
+- `G28` / `G28.2` with W only -> homing hook; the bare `G28` is NOT
+  emitted to gplan (that would mean home-all).
+- `G28.2 X0 Y0 W0` -> emit hook, then keep `G28.2 X0 Y0` for XY homing.
+- A line with both W and XYZ axis words is split into two sequential
+  blocks. Default order: W first, then XYZ. Toggle via the
+  `w_first` constructor arg.
+- Lines inside parens or after `;` are passed through verbatim.
+
+## Configuration
+
+Per-controller config lives at `<ctrl_path>/aux.json` (created on first
+save via the API). Keys:
+
+| Key                    | Default        | Notes                              |
+|------------------------|----------------|------------------------------------|
+| `enabled`              | `false`        | Master switch                      |
+| `port`                 | `/dev/ttyUSB0` | Serial device                      |
+| `baud`                 | `115200`       |                                    |
+| `steps_per_mm`         | `80.0`         | Logical steps per mm               |
+| `dir_sign`             | `1`            | +1 or -1: maps logical+ to motor+  |
+| `min_w`, `max_w`       | `0`, `100`     | Soft limits in mm                  |
+| `home_dir`             | `'-'`          | Direction toward limit switch      |
+| `home_position_mm`     | `0.0`          | mm value assigned at home          |
+| `home_fast_sps`        | `4000`         | Fast seek rate                     |
+| `home_slow_sps`        | `400`          | Slow re-seek rate                  |
+| `home_backoff_steps`   | `200`          | Backoff after touching limit       |
+| `home_maxtravel_steps` | `200000`       | Hard cap on phase 1 seek           |
+| `step_max_sps`         | `4000`         | Cruise rate for STEPS              |
+| `step_accel_sps2`      | `16000`        | Trapezoidal ramp accel             |
+| `step_start_sps`       | `200`          | Ramp floor                         |
+| `limit_low`            | `true`         | Switch active low (closed = LOW)   |
+
+Most of these are pushed to the ESP via `HOMECFG` on connect and
+persisted there in NVS.
+
+## REST API
+
+| Verb | Path                       | Body                  | Effect                 |
+|------|----------------------------|-----------------------|------------------------|
+| GET  | `/api/aux/config`          | -                     | Current config         |
+| PUT  | `/api/aux/config/save`     | `{key: val, ...}`     | Save and re-push       |
+| GET  | `/api/aux/status`          | -                     | `{enabled, present, homed, pos_mm}` |
+| PUT  | `/api/aux/home`            | -                     | Run home cycle (blocks)|
+| PUT  | `/api/aux/abort`           | -                     | Cancel running motion  |
+| PUT  | `/api/aux/jog`             | `{mm: 1.5}` or `{steps: 200}` | Relative move  |
+| PUT  | `/api/aux/move`            | `{mm: 12.5}`          | Absolute move (mm)     |
+| PUT  | `/api/aux/set-zero`        | `{mm: 0}`             | Set current pos to mm  |
+
+Steps-mode jog ignores soft limits (use it to inch the axis to the
+limit switch when the axis isn't homed yet).
+
+## UI
+
+**Control view**
+
+- A jog row appears under the XYZ jog grid when `aux_enabled` is true,
+  with three buttons: `W-`, `W+`, and a wide `Home W`. There is
+  intentionally no separate "set zero" or "W origin" button - homing
+  lands the axis at `home_position_mm` (0 by default), so home and
+  zero are the same point.
+- The DRO table shows a W axis row with position, status (OFFLINE /
+  UNHOMED / HOMED), and a single Home button in the actions column
+  (the cog and map-marker columns are placeholders for layout).
+
+**Settings view**
+
+A "W Axis (auxcnc)" section exposes every aux.json field except
+`enabled` (which stays read-only - flipping the W axis on/off requires
+editingaux.json on the controller, so a fresh install can't surprise
+the user with hardware that isn't there). Saving PUTs the merged
+config to `/api/aux/config/save`, which writes aux.json and pushes
+`HOMECFG` to the ESP. A status line shows whether the axis is
+disabled / offline / connected-unhomed / homed at `<pos> mm`.
+
+## State surface
+
+These are pushed via `state.set` and visible in the websocket stream:
+
+- `aux_enabled` - bool, axis is configured + enabled
+- `aux_present` - bool, ESP responding on serial
+- `aux_homed`   - bool, has been homed since last ESP reset
+- `aux_pos`     - float, current W in mm (4 decimals)
+
+## Edge cases
+
+- **ESP reboots mid-job**: `[boot] auxcnc v=N` banner -> `aux_homed`
+  cleared, message added: "W axis controller restarted - re-home
+  before use". Subsequent W moves still run; if you want a hard fail
+  instead, that's a one-line change in `_require_present`.
+- **Limit switch closed at boot of HOME**: `[home] failed
+  reason=already_at_limit` -> hook raises -> Mach surfaces error.
+- **Pause mid-W-move**: the hook is blocking, so feed-hold takes
+  effect *after* the W move completes. For an immediate stop hit
+  estop; the Hooks listener will call `aux.abort()` which sends
+  `ABORT\n` to the ESP and the step-pulse loop exits.
+- **Connection loss**: if `/dev/ttyUSB0` can't be opened at startup,
+  `aux_present=False` and any G-code with W will fail-fast at the
+  hook handler with "Aux axis not connected".
+- **No home enforcement**: per design, manual jogs and W moves are
+  allowed even without a successful home. Soft limits still apply
+  unless you use the raw step jog endpoint.
+
+## Files added/changed
+
+- `src/py/bbctrl/AuxAxis.py` (new): serial worker + RPC layer
+- `src/py/bbctrl/AuxPreprocessor.py` (new): G-code rewriter
+- `src/py/bbctrl/Hooks.py`: register_internal(), fix the messages
+  listener so `(MSG,HOOK:...)` actually fires
+- `src/py/bbctrl/Ctrl.py`: instantiate AuxAxis, register hooks
+- `src/py/bbctrl/Mach.py`: rewrite MDI commands containing W
+- `src/py/bbctrl/FileHandler.py`: rewrite uploads in place
+- `src/py/bbctrl/Web.py`: REST endpoints
+- `src/py/bbctrl/__init__.py`: export AuxAxis
+- `src/pug/templates/control-view.pug`: W jog row + DRO row
+- `src/js/control-view.js`: aux_home / aux_jog / aux_jog_incr handlers
+- `src/js/axis-vars.js`: `_compute_aux_axis` for W state
+- `src/svelte-components/src/components/WAxisSettings.svelte`: settings panel
+- `src/svelte-components/src/components/SettingsView.svelte`: hosts WAxisSettings
+- `auxcnc/src/main.cpp`: new commands HOME, HOMECFG, WPOS, HOMED?,
+  LIMIT?, ABORT-able STEPS with limit-aware abort, trapezoidal ramps,
+  NVS-persisted config, `[boot]` banner, deterministic reply tokens

docs/mocks/v09_full_ux.html

@@ -0,0 +1,900 @@
+<!doctype html>
+<html lang="en">
+<head>
+<meta charset="utf-8" />
+<meta name="viewport" content="width=device-width,initial-scale=1" />
+<title>Onefinity · V09 · Full UX</title>
+<script src="https://cdn.tailwindcss.com"></script>
+<link rel="stylesheet" href="https://cdn.jsdelivr.net/npm/@fortawesome/fontawesome-free@6.5.2/css/all.min.css" />
+<link href="https://fonts.googleapis.com/css2?family=Inter:wght@400;500;600;700;800;900&family=JetBrains+Mono:wght@500;700&display=swap" rel="stylesheet">
+<style>
+  *{box-sizing:border-box}
+  html,body{margin:0;font-family:'Inter',system-ui,sans-serif;background:#0f172a;color:#e5e7eb}
+  .mono{font-family:'JetBrains Mono',monospace}
+
+  /* ---------- HOST CHROME ---------- */
+  .host{min-height:100vh;display:flex;flex-direction:column;background:radial-gradient(circle at 30% 0%,#374151,#0f172a 60%);}
+  .topbar{display:flex;align-items:center;gap:.6rem;flex-wrap:wrap;padding:.7rem 1rem;background:rgba(255,255,255,.04);border-bottom:1px solid rgba(255,255,255,.08);position:sticky;top:0;z-index:50;backdrop-filter:blur(10px);}
+  .topbar .brand{display:flex;align-items:center;gap:.5rem;font-weight:800;color:#fff}
+  .stripe-logo-sm{background:repeating-linear-gradient(135deg,#a7c7a3 0 6px,transparent 6px 14px);width:26px;height:26px;border-radius:6px}
+  .pill{padding:.3rem .65rem;border-radius:9999px;font-size:.75rem;font-weight:700;background:rgba(255,255,255,.08);color:#cbd5e1}
+  .seg-host{display:inline-flex;background:rgba(255,255,255,.05);border-radius:9999px;padding:3px;gap:3px}
+  .seg-host button{padding:.4rem .85rem;border-radius:9999px;font-size:.78rem;font-weight:700;color:#cbd5e1}
+  .seg-host button.on{background:#fde047;color:#0f172a}
+  .toggle{display:inline-flex;align-items:center;gap:.4rem;padding:.4rem .7rem;border-radius:8px;background:rgba(255,255,255,.08);font-size:.75rem;font-weight:600;color:#e5e7eb;cursor:pointer}
+  .toggle.on{background:#22c55e;color:#0b1220}
+
+  .stage{flex:1;display:flex;align-items:flex-start;justify-content:center;padding:1rem;overflow:auto}
+  .scaler-viewport{position:relative;flex:0 0 auto}
+  .scaler{position:absolute;top:0;left:0;width:1920px;height:auto;transform-origin:top left;transition:transform .2s}
+
+  /* ---------- KIOSK (1920x1080) ---------- */
+  .kiosk{
+    width:1920px;height:1080px;overflow:hidden;border-radius:14px;position:relative;
+    box-shadow:0 30px 60px rgba(0,0,0,.5);
+    display:flex;flex-direction:column;
+    background:#ffffff;color:#0f172a;
+  }
+
+  /* Header */
+  .head{
+    flex:0 0 96px;height:96px;
+    display:flex;align-items:center;gap:18px;
+    padding:0 24px;background:#ffffff;border-bottom:1px solid #e5e7eb;
+  }
+  .brand-blk{display:flex;align-items:center;gap:14px}
+  .menu-btn{width:54px;height:54px;border-radius:12px;background:#f1f5f9;border:1px solid #e2e8f0;color:#0f172a;display:inline-flex;align-items:center;justify-content:center;font-size:1.1rem}
+  .menu-btn:hover{background:#e2e8f0}
+  .brand-logo{width:42px;height:42px;border-radius:8px;background:repeating-linear-gradient(135deg,#a7c7a3 0 6px,transparent 6px 14px)}
+  .brand-name{font-weight:900;font-size:22px;letter-spacing:-.01em}
+
+  /* Underline-ribbon tab style (V02) */
+  .kiosk-tabs{display:inline-flex;gap:0;margin-right:auto;padding-left:18px;align-items:stretch;height:96px}
+  .ktab{
+    position:relative;
+    height:96px;padding:0 26px;
+    background:transparent;border:none;border-radius:0;
+    color:#475569;font-size:1.05rem;font-weight:700;
+    display:inline-flex;align-items:center;gap:.55rem;cursor:pointer;
+    transition:color .15s;
+  }
+  .ktab i{font-size:1.1rem;color:#94a3b8;transition:color .15s}
+  .ktab:hover{color:#0f172a}
+  .ktab:hover i{color:#475569}
+  .ktab.active{color:#0f172a}
+  .ktab.active i{color:#0f172a}
+  .ktab.active::after{
+    content:"";position:absolute;left:14px;right:14px;bottom:0;
+    height:5px;background:#fde047;border-radius:5px 5px 0 0;
+  }
+  .ktab .ktab-badge{background:#fee2e2;color:#991b1b;font-size:.7rem;padding:3px 8px;border-radius:9999px;font-weight:800;line-height:1}
+  .ktab.active .ktab-badge{background:#fde047;color:#0f172a}
+
+  .sys-btn{display:inline-flex;align-items:center;gap:.55rem;height:54px;padding:0 1.1rem;border-radius:14px;background:#f1f5f9;border:1px solid #e2e8f0;color:#0f172a;font-size:.9rem;font-weight:600}
+  .sys-btn .pip{width:9px;height:9px;border-radius:9999px;background:#22c55e}
+  .state-badge{display:inline-flex;align-items:center;gap:.6rem;height:54px;padding:0 1.1rem;border-radius:14px;background:#dcfce7;color:#166534;font-weight:800;font-size:1rem;letter-spacing:.04em}
+  .state-badge .dot{width:10px;height:10px;border-radius:9999px;background:currentColor;position:relative}
+  .state-badge .dot::after{content:"";position:absolute;inset:-3px;border-radius:9999px;border:2px solid currentColor;opacity:.5;animation:pls 1.6s ease-out infinite}
+  @keyframes pls{0%{transform:scale(.7);opacity:.6}100%{transform:scale(2.2);opacity:0}}
+
+  .estop{
+    width:88px;height:88px;background:#dc2626;color:#fff;font-weight:900;
+    clip-path:polygon(30% 0,70% 0,100% 30%,100% 70%,70% 100%,30% 100%,0 70%,0 30%);
+    display:flex;align-items:center;justify-content:center;
+    border:3px solid #fff;box-shadow:0 0 0 3px #b91c1c, 0 8px 20px rgba(220,38,38,.35);font-size:1rem;letter-spacing:.05em
+  }
+
+  /* Body */
+  .body{flex:1;display:flex;flex-direction:column;background:#f1f5f9;min-height:0}
+  .panel{display:none;flex:1;min-height:0;flex-direction:column;padding:18px;gap:14px}
+  .panel.active{display:flex}
+
+  /* ----------------------- V09 jog/macro palette ----------------------- */
+  /* Flat soft slate, no shadow */
+  :root{
+    --jog-bg:#3f4b63;
+    --jog-hover:#4a5777;
+    --jog-dir-bg:#5b6885;
+    --jog-dir-hover:#6a779a;
+    --jog-ghost-bg:#8c97ad;
+    --jog-ghost-hover:#9ba6bb;
+    --jog-ink:#fff;
+    --jog-ghost-ink:#0f172a;
+  }
+
+  /* JOG */
+  .jog-card{background:#fff;border:1px solid #e5e7eb;border-radius:18px;display:flex;flex-direction:column;padding:18px;min-height:0}
+  .jog-head{display:flex;align-items:center;justify-content:space-between;margin-bottom:14px}
+  .jog-title{font-size:18px;font-weight:700;color:#0f172a}
+  .jog-title .step{color:#0ea5e9;font-family:'JetBrains Mono',monospace}
+  .step-seg{display:inline-flex;background:#f1f5f9;border:1px solid #e2e8f0;border-radius:14px;padding:4px}
+  .step-seg button{height:48px;min-width:64px;padding:0 1rem;border-radius:11px;font-size:1rem;font-weight:800;color:#475569;cursor:pointer}
+  .step-seg button.active{background:#0f172a;color:#fde047}
+  .jog-grid{display:grid;grid-template-columns:repeat(4,1fr);grid-template-rows:repeat(4,1fr);gap:10px;flex:1;min-height:0}
+  .jbtn{
+    border-radius:16px;display:flex;flex-direction:column;align-items:center;justify-content:center;gap:4px;
+    user-select:none;-webkit-tap-highlight-color:transparent;cursor:pointer;
+    font-weight:700;font-size:1.05rem;border:none;
+    transition:transform .06s, background .15s;
+    background:var(--jog-bg);color:var(--jog-ink);
+  }
+  .jbtn:hover{background:var(--jog-hover)}
+  .jbtn:active{transform:scale(.97)}
+  .jbtn .ico{font-size:1.6rem}
+  .jbtn .lbl{font-size:.8rem;color:inherit;opacity:.85;font-weight:600}
+  .jbtn.dir{background:var(--jog-dir-bg)} .jbtn.dir:hover{background:var(--jog-dir-hover)}
+  .jbtn.ghost{background:var(--jog-ghost-bg);color:var(--jog-ghost-ink)} .jbtn.ghost:hover{background:var(--jog-ghost-hover)}
+
+  /* DRO + STATUS */
+  .control-grid{display:grid;grid-template-columns:720px 1fr;gap:18px;flex:1;min-height:0}
+  .right-col{display:grid;grid-template-rows:1fr 158px;gap:18px;min-height:0}
+  .dro-card{background:#fff;border:1px solid #e5e7eb;border-radius:18px;overflow:hidden;display:flex;flex-direction:column}
+  .dro-head{display:grid;grid-template-columns:84px 1.4fr 1fr 1fr 170px 170px 280px;column-gap:.75rem;align-items:center;padding:14px 22px;background:#f8fafc;border-bottom:1px solid #e5e7eb;font-size:.78rem;font-weight:800;text-transform:uppercase;letter-spacing:.1em;color:#94a3b8}
+  .dro-row{display:grid;grid-template-columns:84px 1.4fr 1fr 1fr 170px 170px 280px;column-gap:.75rem;align-items:center;padding:14px 22px;border-bottom:1px solid #f1f5f9;flex:1;min-height:0}
+  .dro-row:last-child{border-bottom:none}
+  .dro-axis{font-weight:900;font-size:46px;line-height:1}
+  .dro-pos{font-family:'JetBrains Mono',monospace;font-size:36px;font-weight:800}
+  .dro-pos .u{font-size:14px;color:#94a3b8;font-weight:500;margin-left:6px}
+  .dro-sec{font-family:'JetBrains Mono',monospace;font-size:18px;color:#64748b;font-weight:600}
+  .axis-x{color:#dc2626} .axis-y{color:#16a34a} .axis-z{color:#2563eb} .axis-w{color:#7c3aed}
+
+  .chip{display:inline-flex;align-items:center;gap:.4rem;padding:.4rem .7rem;border-radius:9999px;font-size:.78rem;font-weight:700}
+  .chip-green{background:#dcfce7;color:#166534}
+  .chip-amber{background:#fef3c7;color:#92400e}
+  .chip-red{background:#fee2e2;color:#991b1b}
+  .chip-slate{background:#e2e8f0;color:#334155}
+  .chip-blue{background:#dbeafe;color:#1e40af}
+
+  .icon-btn{
+    width:72px;height:72px;border-radius:14px;cursor:pointer;
+    display:inline-flex;align-items:center;justify-content:center;
+    color:#334155;background:#f1f5f9;border:1px solid #e2e8f0;
+    font-size:1.45rem
+  }
+  .icon-btn:hover{background:#e2e8f0}
+  .actions-cell{display:flex;justify-content:flex-end;gap:10px}
+  .z-highlight{background:rgba(254,243,199,.4)}
+
+  .status-strip{display:grid;grid-template-columns:repeat(4,1fr);gap:18px;min-height:0}
+  .stat-card{background:#fff;border:1px solid #e5e7eb;border-radius:18px;padding:18px 22px;display:flex;flex-direction:column;justify-content:center}
+  .stat-label{font-size:11px;font-weight:800;text-transform:uppercase;letter-spacing:.14em;color:#94a3b8}
+  .stat-val{font-family:'JetBrains Mono',monospace;font-size:30px;font-weight:800;margin-top:6px}
+  .stat-val.ok{color:#166534}
+  .stat-sub{font-size:13px;color:#64748b;margin-top:2px}
+
+  /* MACROS */
+  .macro-row{display:grid;grid-template-columns:repeat(8,1fr);gap:12px;flex:0 0 auto}
+  .macro-btn{
+    height:84px;border-radius:14px;border:none;cursor:pointer;
+    color:#fff;background:#3f4b63;
+    font-weight:800;font-size:1rem;
+    display:flex;align-items:center;justify-content:center;gap:.6rem;
+    transition:transform .06s, background .15s
+  }
+  .macro-btn:hover{background:#4a5777}
+  .macro-btn:active{transform:translateY(2px)}
+  .macro-btn .mnum{display:inline-flex;align-items:center;justify-content:center;width:28px;height:28px;border-radius:8px;background:#fde047;color:#0f172a;font-size:.85rem;font-weight:900}
+  .macro-btn .micon{font-size:1.1rem;opacity:.75}
+
+  /* =============================================================
+     PROGRAM PANEL
+     ============================================================= */
+  .program-card{background:#fff;border:1px solid #e5e7eb;border-radius:18px;display:flex;flex-direction:column;flex:1;min-height:0;overflow:hidden}
+  .ptab-bar{display:flex;align-items:center;gap:6px;border-bottom:1px solid #e5e7eb;flex:0 0 auto;background:#fff;padding:0 18px}
+  .ptab{height:60px;padding:0 22px;font-weight:700;color:#64748b;border-bottom:3px solid transparent;font-size:1rem;display:inline-flex;align-items:center;gap:.5rem;cursor:pointer}
+  .ptab:hover{color:#0f172a}
+  .ptab.active{color:#0f172a;border-bottom-color:#0f172a}
+  .ptab .ptab-badge{background:#fde047;color:#0f172a;font-size:.7rem;padding:2px 7px;border-radius:9999px;font-weight:900}
+
+  .action-bar{display:flex;align-items:center;gap:12px;padding:18px;flex-wrap:wrap;border-bottom:1px solid #f1f5f9}
+  .action-btn{height:84px;padding:0 24px;border-radius:14px;background:#3f4b63;color:#fff;border:none;cursor:pointer;display:inline-flex;flex-direction:column;align-items:center;justify-content:center;gap:4px;font-weight:800;font-size:.9rem;letter-spacing:.04em;transition:background .15s}
+  .action-btn:hover{background:#4a5777}
+  .action-btn .ico{font-size:1.4rem}
+  .action-btn.run{background:#16a34a}
+  .action-btn.run:hover{background:#15803d}
+  .action-btn.stop{background:#0f172a}
+  .action-btn.stop:hover{background:#1e293b}
+  .action-btn.danger{background:#fee2e2;color:#7f1d1d}
+  .action-btn.danger:hover{background:#fecaca}
+  .action-btn.danger .ico{color:#dc2626}
+
+  .file-bar{display:flex;align-items:center;gap:10px;padding:14px 18px;flex-wrap:wrap;border-bottom:1px solid #f1f5f9}
+  .file-btn{height:54px;padding:0 18px;border-radius:12px;background:#f1f5f9;border:1px solid #e2e8f0;font-weight:700;color:#0f172a;font-size:.9rem;display:inline-flex;align-items:center;gap:.5rem;cursor:pointer}
+  .file-btn:hover{background:#e2e8f0}
+  .file-select{height:54px;padding:0 16px;border-radius:12px;background:#fff;border:1px solid #e2e8f0;font-weight:600;color:#0f172a;font-size:.9rem;display:inline-flex;align-items:center;gap:.5rem;cursor:pointer}
+  .file-select .caret{color:#94a3b8;margin-left:.5rem}
+  .file-select.primary{background:#fff;border:2px solid #0ea5e9;flex:1;min-width:300px}
+
+  .program-body{flex:1;display:grid;grid-template-columns:1fr 600px;min-height:0}
+  .gcode{font-family:'JetBrains Mono',monospace;font-size:14px;line-height:1.6;background:#fafafa;border-right:1px solid #f1f5f9;padding:14px 0;overflow:auto;color:#1e293b}
+  .gline{display:grid;grid-template-columns:60px 1fr;gap:14px;padding:1px 18px 1px 0}
+  .gline:nth-child(odd){background:#f4f4f5}
+  .gline .gn{color:#f59e0b;text-align:right;font-weight:700}
+  .gline.cur{background:#dbeafe !important}
+  .gline.cur .gn{color:#1e40af}
+  .gcomment{color:#64748b}
+  .gword{color:#0f172a}
+  .gnum{color:#16a34a}
+
+  .viewer{display:flex;flex-direction:column;min-height:0}
+  .viewer-3d{flex:1;background:#0b1220;position:relative;overflow:hidden;display:flex;align-items:center;justify-content:center}
+  .viewer-tools{display:flex;gap:8px;padding:14px;border-top:1px solid #f1f5f9;background:#fff;flex-wrap:wrap}
+  .vtool{height:60px;width:60px;border-radius:12px;background:#f1f5f9;border:1px solid #e2e8f0;color:#475569;display:inline-flex;align-items:center;justify-content:center;font-size:1.2rem;cursor:pointer}
+  .vtool:hover{background:#e2e8f0}
+  .vtool.on{background:#0f172a;color:#fff;border-color:#0f172a}
+  .vinfo{padding:14px 18px;background:#fff;font-size:13px;color:#64748b;border-top:1px solid #f1f5f9;display:flex;justify-content:space-between;align-items:center}
+  .vinfo .ext{color:#0f172a;font-weight:600}
+
+  /* =============================================================
+     MESSAGES PANEL
+     ============================================================= */
+  .messages{display:none;flex-direction:column;flex:1;min-height:0;padding:18px;gap:12px;overflow:auto}
+  .messages.active{display:flex}
+  .msg{background:#fff;border:1px solid #e5e7eb;border-radius:14px;padding:18px 22px;display:grid;grid-template-columns:54px 1fr auto;gap:18px;align-items:flex-start}
+  .msg .mi{width:54px;height:54px;border-radius:12px;display:inline-flex;align-items:center;justify-content:center;font-size:1.4rem}
+  .msg.error{border-left:6px solid #dc2626}
+  .msg.error .mi{background:#fee2e2;color:#991b1b}
+  .msg.warn{border-left:6px solid #f59e0b}
+  .msg.warn .mi{background:#fef3c7;color:#92400e}
+  .msg.info{border-left:6px solid #0ea5e9}
+  .msg.info .mi{background:#dbeafe;color:#1e40af}
+  .msg.ok{border-left:6px solid #16a34a}
+  .msg.ok .mi{background:#dcfce7;color:#166534}
+  .msg .mtitle{font-weight:800;font-size:1.05rem;color:#0f172a}
+  .msg .mtime{font-size:.8rem;color:#94a3b8;margin-top:2px}
+  .msg .mbody{margin-top:6px;color:#475569;font-size:.95rem;line-height:1.5}
+  .msg .mbody .mono{background:#f1f5f9;padding:2px 6px;border-radius:4px;font-size:.85rem}
+  .msg .mactions{display:flex;gap:8px}
+  .mbtn{height:48px;padding:0 16px;border-radius:10px;background:#f1f5f9;border:1px solid #e2e8f0;font-weight:700;color:#0f172a;font-size:.85rem;cursor:pointer}
+  .mbtn:hover{background:#e2e8f0}
+  .mbtn.primary{background:#0f172a;color:#fff;border-color:#0f172a}
+  .mbtn.primary:hover{background:#1e293b}
+
+  /* =============================================================
+     INDICATORS PANEL
+     ============================================================= */
+  .indicators{display:none;flex:1;min-height:0;padding:18px;gap:14px;overflow:auto;grid-template-columns:repeat(4,1fr);grid-auto-rows:min-content}
+  .indicators.active{display:grid}
+  .ind{background:#fff;border:1px solid #e5e7eb;border-radius:14px;padding:16px 18px;display:flex;flex-direction:column;gap:6px}
+  .ind-label{font-size:.8rem;font-weight:800;text-transform:uppercase;letter-spacing:.1em;color:#94a3b8}
+  .ind-val{font-family:'JetBrains Mono',monospace;font-size:1.6rem;font-weight:800;color:#0f172a}
+  .ind-state{display:inline-flex;align-items:center;gap:.4rem;font-size:.8rem;font-weight:700;color:#475569}
+  .ind-state .dot{width:10px;height:10px;border-radius:9999px}
+  .ind .progress{height:8px;background:#f1f5f9;border-radius:9999px;overflow:hidden;margin-top:4px}
+  .ind .progress > div{height:100%;background:#0ea5e9}
+  .ind.full{grid-column:span 2}
+
+  /* =============================================================
+     MDI PANEL
+     ============================================================= */
+  .mdi{display:none;flex-direction:column;flex:1;min-height:0;padding:18px;gap:14px}
+  .mdi.active{display:flex}
+  .mdi-input{
+    background:#0b1220;color:#86efac;border:1px solid #1e293b;border-radius:14px;
+    padding:22px 24px;font-family:'JetBrains Mono',monospace;font-size:1.4rem;font-weight:600;
+    display:flex;align-items:center;gap:.6rem;
+  }
+  .mdi-input .prompt{color:#475569}
+  .mdi-input .cursor{display:inline-block;width:14px;height:1.4rem;background:#86efac;animation:blink 1s steps(2,end) infinite;vertical-align:middle}
+  @keyframes blink{50%{opacity:0}}
+  .mdi-keys{display:grid;grid-template-columns:repeat(8,1fr);gap:8px;flex:0 0 auto}
+  .mkey{height:64px;border-radius:12px;background:#fff;border:1px solid #e2e8f0;font-weight:800;font-size:1.05rem;color:#0f172a;cursor:pointer;font-family:'JetBrains Mono',monospace}
+  .mkey:hover{background:#f1f5f9}
+  .mkey.send{background:#16a34a;color:#fff;border-color:#15803d;grid-column:span 2;font-family:'Inter',sans-serif;font-size:.95rem;letter-spacing:.04em}
+  .mkey.send:hover{background:#15803d}
+  .mkey.clear{background:#fee2e2;color:#7f1d1d;border-color:#fca5a5;font-family:'Inter',sans-serif;font-size:.95rem;letter-spacing:.04em}
+  .mdi-history{flex:1;background:#fff;border:1px solid #e5e7eb;border-radius:14px;padding:14px 18px;overflow:auto;font-family:'JetBrains Mono',monospace;font-size:.95rem}
+  .mdi-history .h-row{display:grid;grid-template-columns:80px 1fr auto;gap:14px;padding:6px 0;border-bottom:1px solid #f1f5f9;align-items:center}
+  .mdi-history .h-time{color:#94a3b8;font-size:.8rem}
+  .mdi-history .h-cmd{color:#0f172a;font-weight:700}
+  .mdi-history .h-status{color:#16a34a;font-weight:700;font-size:.8rem}
+  .mdi-history .h-status.err{color:#dc2626}
+
+  /* =============================================================
+     SETTINGS PANEL
+     ============================================================= */
+  .settings{display:none;flex:1;min-height:0;padding:18px;gap:14px;overflow:auto;grid-template-columns:280px 1fr}
+  .settings.active{display:grid}
+  .set-side{background:#fff;border:1px solid #e5e7eb;border-radius:14px;padding:10px;display:flex;flex-direction:column;gap:4px;height:fit-content}
+  .set-item{height:56px;padding:0 16px;border-radius:10px;display:flex;align-items:center;gap:.6rem;color:#475569;font-weight:700;cursor:pointer}
+  .set-item:hover{background:#f1f5f9}
+  .set-item.active{background:#0f172a;color:#fff}
+  .set-content{display:flex;flex-direction:column;gap:14px}
+  .set-card{background:#fff;border:1px solid #e5e7eb;border-radius:14px;padding:22px}
+  .set-title{font-weight:800;font-size:1.1rem;color:#0f172a;margin-bottom:14px}
+  .set-row{display:grid;grid-template-columns:280px 1fr auto;gap:14px;align-items:center;padding:14px 0;border-bottom:1px solid #f1f5f9}
+  .set-row:last-child{border-bottom:none}
+  .set-row .label{font-weight:700;color:#0f172a;font-size:.95rem}
+  .set-row .desc{color:#64748b;font-size:.85rem;margin-top:2px}
+  .set-row .val{font-family:'JetBrains Mono',monospace;color:#475569}
+  .set-input{height:48px;padding:0 14px;border-radius:10px;border:1px solid #e2e8f0;background:#fff;font-family:'JetBrains Mono',monospace;font-size:.95rem;color:#0f172a;min-width:200px}
+  .set-toggle{width:54px;height:30px;border-radius:9999px;background:#cbd5e1;position:relative;cursor:pointer;transition:background .15s}
+  .set-toggle::after{content:"";position:absolute;left:3px;top:3px;width:24px;height:24px;border-radius:9999px;background:#fff;transition:transform .15s}
+  .set-toggle.on{background:#16a34a}
+  .set-toggle.on::after{transform:translateX(24px)}
+</style>
+</head>
+<body>
+<div class="host">
+
+<div class="topbar">
+  <div class="brand">
+    <div class="stripe-logo-sm"></div>
+    ONEFINITY · V09 · Full UX preview
+  </div>
+  <span class="pill">Click the inner tabs to navigate</span>
+  <div style="margin-left:auto"></div>
+  <button id="oneToOne" class="toggle">1:1</button>
+  <button id="fitBtn" class="toggle on">Fit</button>
+  <span id="scaleInfo" class="pill mono">100%</span>
+</div>
+
+<div class="stage" id="stage">
+  <div class="scaler-viewport" id="viewport">
+    <div class="scaler" id="scaler">
+
+      <!-- ============= KIOSK ============= -->
+      <div class="kiosk">
+        <header class="head">
+          <div class="brand-blk">
+            <div class="brand-logo"></div>
+            <div class="brand-name">ONEFINITY</div>
+          </div>
+          <div class="kiosk-tabs">
+            <button class="ktab active" data-target="control"><i class="fa-solid fa-gamepad"></i> Control</button>
+            <button class="ktab" data-target="program"><i class="fa-solid fa-list-ol"></i> Program</button>
+            <button class="ktab" data-target="console"><i class="fa-solid fa-terminal"></i> Console <span class="ktab-badge">2</span></button>
+            <button class="ktab" data-target="settings"><i class="fa-solid fa-sliders"></i> Settings</button>
+          </div>
+          <button class="sys-btn"><span class="pip"></span> All systems · view <i class="fa-solid fa-chevron-down" style="font-size:10px;opacity:.6"></i></button>
+          <span class="state-badge"><span class="dot"></span> READY</span>
+          <button class="estop">STOP</button>
+        </header>
+
+        <div class="body">
+
+          <!-- ============= CONTROL ============= -->
+          <div class="panel active" data-panel="control">
+            <div class="control-grid">
+              <!-- jog -->
+              <div class="jog-card">
+                <div class="jog-head">
+                  <div class="jog-title">Jog · step <span class="step">10mm</span></div>
+                  <div class="step-seg">
+                    <button>0.1</button><button>1</button><button class="active">10</button><button>100</button>
+                  </div>
+                </div>
+                <div class="jog-grid">
+                  <button class="jbtn dir"><i class="fa-solid fa-arrow-up ico" style="transform:rotate(-45deg)"></i></button>
+                  <button class="jbtn">Y+</button>
+                  <button class="jbtn dir"><i class="fa-solid fa-arrow-up ico" style="transform:rotate(45deg)"></i></button>
+                  <button class="jbtn">Z+</button>
+                  <button class="jbtn">X−</button>
+                  <button class="jbtn ghost"><span class="lbl">XY</span><span style="font-size:1rem;font-weight:700">Origin</span></button>
+                  <button class="jbtn">X+</button>
+                  <button class="jbtn ghost"><span class="lbl">Z</span><span style="font-size:1rem;font-weight:700">Origin</span></button>
+                  <button class="jbtn dir"><i class="fa-solid fa-arrow-down ico" style="transform:rotate(45deg)"></i></button>
+                  <button class="jbtn">Y−</button>
+                  <button class="jbtn dir"><i class="fa-solid fa-arrow-down ico" style="transform:rotate(-45deg)"></i></button>
+                  <button class="jbtn">Z−</button>
+                  <button class="jbtn"><i class="fa-solid fa-arrow-down ico"></i><span class="lbl">W−</span></button>
+                  <button class="jbtn ghost"><span class="lbl">W</span><span style="font-size:1rem;font-weight:700">Origin</span></button>
+                  <button class="jbtn"><i class="fa-solid fa-arrow-up ico"></i><span class="lbl">W+</span></button>
+                  <button class="jbtn"><i class="fa-solid fa-house ico"></i><span class="lbl">Home</span></button>
+                </div>
+              </div>
+
+              <!-- DRO + status -->
+              <div class="right-col">
+                <div class="dro-card">
+                  <div class="dro-head">
+                    <div>Axis</div><div>Position</div><div>Absolute</div><div>Offset</div><div>State</div><div>Toolpath</div><div style="text-align:right">Actions</div>
+                  </div>
+                  <div class="dro-row">
+                    <div class="dro-axis axis-x">X</div>
+                    <div class="dro-pos">0.000<span class="u">mm</span></div>
+                    <div class="dro-sec">0.000</div>
+                    <div class="dro-sec">0.000</div>
+                    <div><span class="chip chip-amber"><i class="fa-solid fa-question"></i> Unhomed</span></div>
+                    <div><span class="chip chip-green"><i class="fa-solid fa-check"></i> OK</span></div>
+                    <div class="actions-cell">
+                      <button class="icon-btn"><i class="fa-solid fa-gear"></i></button>
+                      <button class="icon-btn"><i class="fa-solid fa-location-dot"></i></button>
+                      <button class="icon-btn"><i class="fa-solid fa-house"></i></button>
+                    </div>
+                  </div>
+                  <div class="dro-row">
+                    <div class="dro-axis axis-y">Y</div>
+                    <div class="dro-pos">0.000<span class="u">mm</span></div>
+                    <div class="dro-sec">0.000</div>
+                    <div class="dro-sec">0.000</div>
+                    <div><span class="chip chip-amber"><i class="fa-solid fa-question"></i> Unhomed</span></div>
+                    <div><span class="chip chip-green"><i class="fa-solid fa-check"></i> OK</span></div>
+                    <div class="actions-cell">
+                      <button class="icon-btn"><i class="fa-solid fa-gear"></i></button>
+                      <button class="icon-btn"><i class="fa-solid fa-location-dot"></i></button>
+                      <button class="icon-btn"><i class="fa-solid fa-house"></i></button>
+                    </div>
+                  </div>
+                  <div class="dro-row z-highlight">
+                    <div class="dro-axis axis-z">Z</div>
+                    <div class="dro-pos">0.000<span class="u">mm</span></div>
+                    <div class="dro-sec">0.000</div>
+                    <div class="dro-sec">0.000</div>
+                    <div><span class="chip chip-amber"><i class="fa-solid fa-question"></i> Unhomed</span></div>
+                    <div><span class="chip chip-amber"><i class="fa-solid fa-triangle-exclamation"></i> Over</span></div>
+                    <div class="actions-cell">
+                      <button class="icon-btn"><i class="fa-solid fa-gear"></i></button>
+                      <button class="icon-btn"><i class="fa-solid fa-location-dot"></i></button>
+                      <button class="icon-btn"><i class="fa-solid fa-house"></i></button>
+                    </div>
+                  </div>
+                  <div class="dro-row">
+                    <div class="dro-axis axis-w">W</div>
+                    <div class="dro-pos">0.000<span class="u">mm</span></div>
+                    <div class="dro-sec">0.000</div>
+                    <div class="dro-sec" style="opacity:.4">—</div>
+                    <div><span class="chip chip-amber"><i class="fa-solid fa-question"></i> Unhomed</span></div>
+                    <div><span class="chip chip-green"><i class="fa-solid fa-check"></i> OK</span></div>
+                    <div class="actions-cell">
+                      <button class="icon-btn"><i class="fa-solid fa-location-dot"></i></button>
+                      <button class="icon-btn"><i class="fa-solid fa-house"></i></button>
+                    </div>
+                  </div>
+                </div>
+
+                <div class="status-strip">
+                  <div class="stat-card"><div class="stat-label">State</div><div class="stat-val ok">READY</div><div class="stat-sub">No alerts</div></div>
+                  <div class="stat-card"><div class="stat-label">Velocity / Feed</div><div class="stat-val">0 · 0</div><div class="stat-sub">m/min · mm/min</div></div>
+                  <div class="stat-card"><div class="stat-label">Spindle</div><div class="stat-val">0 (0)</div><div class="stat-sub">RPM (commanded / actual)</div></div>
+                  <div class="stat-card"><div class="stat-label">Job</div><div class="stat-val">0 / 1,785</div><div class="stat-sub">Line · 19:07 remaining</div></div>
+                </div>
+              </div>
+            </div>
+
+            <!-- macros -->
+            <div class="macro-row">
+              <button class="macro-btn"><span class="mnum">1</span><i class="fa-solid fa-circle-play micon"></i> Macro 1</button>
+              <button class="macro-btn"><span class="mnum">2</span><i class="fa-solid fa-circle-play micon"></i> Macro 2</button>
+              <button class="macro-btn"><span class="mnum">3</span><i class="fa-solid fa-circle-play micon"></i> Macro 3</button>
+              <button class="macro-btn"><span class="mnum">4</span><i class="fa-solid fa-circle-play micon"></i> Macro 4</button>
+              <button class="macro-btn"><span class="mnum">5</span><i class="fa-solid fa-circle-play micon"></i> Macro 5</button>
+              <button class="macro-btn"><span class="mnum">6</span><i class="fa-solid fa-circle-play micon"></i> Macro 6</button>
+              <button class="macro-btn"><span class="mnum">7</span><i class="fa-solid fa-circle-play micon"></i> Macro 7</button>
+              <button class="macro-btn"><span class="mnum">8</span><i class="fa-solid fa-circle-play micon"></i> Macro 8</button>
+            </div>
+          </div>
+
+          <!-- ============= PROGRAM ============= -->
+          <div class="panel" data-panel="program" style="padding:0;gap:0">
+            <div class="program-card" style="margin:18px;border-radius:18px">
+              <!-- Auto sub-panel -->
+              <div class="auto-sub" data-sub="auto" style="display:flex;flex-direction:column;flex:1;min-height:0">
+                <div class="action-bar">
+                  <button class="action-btn run"><i class="fa-solid fa-play ico"></i><span>RUN</span></button>
+                  <button class="action-btn stop"><i class="fa-solid fa-stop ico"></i><span>STOP</span></button>
+                  <button class="action-btn"><i class="fa-solid fa-folder-arrow-up ico"></i><span>UPLOAD FOLDER</span></button>
+                  <button class="action-btn"><i class="fa-solid fa-file-arrow-up ico"></i><span>UPLOAD FILE</span></button>
+                  <button class="action-btn"><i class="fa-solid fa-file-arrow-down ico"></i><span>DOWNLOAD FILE</span></button>
+                  <button class="action-btn danger"><i class="fa-solid fa-trash ico"></i><span>DELETE</span></button>
+                </div>
+
+                <div class="file-bar">
+                  <button class="file-btn"><i class="fa-solid fa-folder-plus"></i> Create Folder</button>
+                  <button class="file-btn"><i class="fa-solid fa-folder-minus"></i> Delete Folder</button>
+                  <span class="file-select"><i class="fa-solid fa-folder-open" style="color:#64748b"></i> Default folder <i class="fa-solid fa-chevron-down caret"></i></span>
+                  <span class="file-select primary"><i class="fa-solid fa-file-code" style="color:#0ea5e9"></i> thin-rough.nc <i class="fa-solid fa-chevron-down caret" style="margin-left:auto"></i></span>
+                  <span class="file-select"><i class="fa-solid fa-arrow-down-wide-short" style="color:#64748b"></i> By Upload Date <i class="fa-solid fa-chevron-down caret"></i></span>
+                </div>
+
+                <div class="program-body">
+                  <div class="gcode" id="gcode-list"></div>
+                  <div class="viewer">
+                    <div class="viewer-3d">
+                      <svg viewBox="0 0 400 220" style="width:100%;height:100%">
+                        <defs>
+                          <pattern id="gridv" width="20" height="20" patternUnits="userSpaceOnUse">
+                            <path d="M 20 0 L 0 0 0 20" fill="none" stroke="#1e293b" stroke-width="1"/>
+                          </pattern>
+                        </defs>
+                        <rect width="400" height="220" fill="url(#gridv)"/>
+                        <rect x="40" y="80" width="320" height="60" stroke="#475569" stroke-width="1" fill="none" stroke-dasharray="3 3"/>
+                        <text x="40" y="74" fill="#64748b" font-size="9" font-family="monospace">Stock: 250 × 25 × 16 mm</text>
+                        <!-- toolpath -->
+                        <path d="M40,110 L360,110 M40,100 L360,100 M40,120 L360,120 M40,90 L360,90 M40,130 L360,130" stroke="#22c55e" stroke-width="1.4" fill="none" opacity=".8"/>
+                        <path d="M40,110 L40,80 L60,80 L60,110 M80,110 L80,80 L100,80 L100,110 M120,110 L120,80 L140,80 L140,110" stroke="#ef4444" stroke-width="1.4" fill="none" opacity=".8"/>
+                        <circle cx="40" cy="110" r="3" fill="#22c55e"/>
+                        <circle cx="360" cy="110" r="3" fill="#ef4444"/>
+                        <text x="46" y="108" fill="#22c55e" font-size="8" font-family="monospace">START</text>
+                        <text x="332" y="108" fill="#ef4444" font-size="8" font-family="monospace">END</text>
+                        <!-- axes gizmo -->
+                        <g transform="translate(28,196)">
+                          <line x1="0" y1="0" x2="22" y2="0" stroke="#ef4444" stroke-width="2"/>
+                          <line x1="0" y1="0" x2="0" y2="-22" stroke="#3b82f6" stroke-width="2"/>
+                          <line x1="0" y1="0" x2="-12" y2="12" stroke="#22c55e" stroke-width="2"/>
+                          <text x="24" y="4" fill="#ef4444" font-size="9" font-family="monospace">X</text>
+                          <text x="-4" y="-26" fill="#3b82f6" font-size="9" font-family="monospace">Z</text>
+                          <text x="-22" y="22" fill="#22c55e" font-size="9" font-family="monospace">Y</text>
+                        </g>
+                      </svg>
+                    </div>
+                    <div class="viewer-tools">
+                      <button class="vtool" title="Fit"><i class="fa-solid fa-expand"></i></button>
+                      <button class="vtool on" title="Tool"><i class="fa-solid fa-screwdriver-wrench"></i></button>
+                      <button class="vtool" title="Stock"><i class="fa-solid fa-cube"></i></button>
+                      <button class="vtool" title="Origin"><i class="fa-solid fa-up-right-and-down-left-from-center"></i></button>
+                      <button class="vtool" title="Top"><i class="fa-solid fa-square"></i></button>
+                      <button class="vtool" title="Front"><i class="fa-solid fa-square-full"></i></button>
+                      <button class="vtool" title="Iso"><i class="fa-solid fa-cubes"></i></button>
+                    </div>
+                    <div class="vinfo">
+                      <span><span class="ext">thin-rough.nc</span> · 1,785 lines · 12.4 KB</span>
+                      <span class="mono">est. 19:07</span>
+                    </div>
+                  </div>
+                </div>
+              </div>
+
+            </div>
+          </div>
+
+          <!-- ============= CONSOLE ============= -->
+          <div class="panel" data-panel="console" style="padding:0;gap:0">
+            <div class="program-card" style="margin:18px;border-radius:18px">
+
+              <div class="ptab-bar">
+                <button class="ptab active" data-ptab="mdi"><i class="fa-solid fa-keyboard"></i> MDI</button>
+                <button class="ptab" data-ptab="messages"><i class="fa-solid fa-comment-dots"></i> Messages <span class="ptab-badge">2</span></button>
+                <button class="ptab" data-ptab="indicators"><i class="fa-solid fa-bell"></i> Indicators</button>
+              </div>
+
+              <!-- MDI sub-panel -->
+              <div class="mdi active" data-sub="mdi">
+                <div class="mdi-input">
+                  <span class="prompt">G&gt;</span>
+                  <span class="mono">G0 X100 Y50 F2000</span>
+                  <span class="cursor"></span>
+                </div>
+                <div class="mdi-keys">
+                  <button class="mkey">G0</button>
+                  <button class="mkey">G1</button>
+                  <button class="mkey">G2</button>
+                  <button class="mkey">G3</button>
+                  <button class="mkey">G28</button>
+                  <button class="mkey">G92</button>
+                  <button class="mkey">M3</button>
+                  <button class="mkey">M5</button>
+                  <button class="mkey">X</button>
+                  <button class="mkey">Y</button>
+                  <button class="mkey">Z</button>
+                  <button class="mkey">W</button>
+                  <button class="mkey">F</button>
+                  <button class="mkey">S</button>
+                  <button class="mkey clear">CLEAR</button>
+                  <button class="mkey send">SEND ↵</button>
+                </div>
+                <div class="mdi-history">
+                  <div class="h-row"><span class="h-time">19:42:11</span><span class="h-cmd">G21</span><span class="h-status">✓ ok</span></div>
+                  <div class="h-row"><span class="h-time">19:42:14</span><span class="h-cmd">G90</span><span class="h-status">✓ ok</span></div>
+                  <div class="h-row"><span class="h-time">19:43:02</span><span class="h-cmd">G0 Y12.800</span><span class="h-status">✓ ok</span></div>
+                  <div class="h-row"><span class="h-time">19:43:08</span><span class="h-cmd">G0 Z19.040</span><span class="h-status">✓ ok</span></div>
+                  <div class="h-row"><span class="h-time">19:43:30</span><span class="h-cmd">G1 Z-20 F800</span><span class="h-status err">✗ blocked: Z over travel</span></div>
+                  <div class="h-row"><span class="h-time">19:44:01</span><span class="h-cmd">G0 Z5</span><span class="h-status">✓ ok</span></div>
+                </div>
+              </div>
+
+              <!-- Messages sub-panel -->
+              <div class="messages" data-sub="messages">
+                <div class="msg warn">
+                  <div class="mi"><i class="fa-solid fa-triangle-exclamation"></i></div>
+                  <div>
+                    <div style="display:flex;align-items:baseline;gap:.6rem">
+                      <div class="mtitle">Z toolpath exceeds soft-limit</div>
+                      <div class="mtime">2 min ago · sticky</div>
+                    </div>
+                    <div class="mbody">Loaded program reaches <span class="mono">Z = -16.500</span>. Configured soft-limit is <span class="mono">Z = -15.000</span>. Adjust the Z origin or set a deeper soft-limit before running.</div>
+                  </div>
+                  <div class="mactions">
+                    <button class="mbtn">Open settings</button>
+                    <button class="mbtn primary">Acknowledge</button>
+                  </div>
+                </div>
+
+                <div class="msg info">
+                  <div class="mi"><i class="fa-solid fa-circle-info"></i></div>
+                  <div>
+                    <div style="display:flex;align-items:baseline;gap:.6rem">
+                      <div class="mtitle">Camera offline</div>
+                      <div class="mtime">12 min ago</div>
+                    </div>
+                    <div class="mbody">Camera at <span class="mono">10.1.10.55:8554</span> did not respond on last poll. Live preview disabled.</div>
+                  </div>
+                  <div class="mactions">
+                    <button class="mbtn">Retry</button>
+                    <button class="mbtn">Dismiss</button>
+                  </div>
+                </div>
+
+                <div class="msg ok">
+                  <div class="mi"><i class="fa-solid fa-check"></i></div>
+                  <div>
+                    <div style="display:flex;align-items:baseline;gap:.6rem">
+                      <div class="mtitle">File uploaded · thin-rough.nc</div>
+                      <div class="mtime">21 min ago</div>
+                    </div>
+                    <div class="mbody">1,785 lines · 12.4 KB · checksum verified.</div>
+                  </div>
+                  <div class="mactions">
+                    <button class="mbtn">Open</button>
+                  </div>
+                </div>
+
+                <div class="msg error">
+                  <div class="mi"><i class="fa-solid fa-circle-xmark"></i></div>
+                  <div>
+                    <div style="display:flex;align-items:baseline;gap:.6rem">
+                      <div class="mtitle">WiFi: not connected</div>
+                      <div class="mtime">1 h ago</div>
+                    </div>
+                    <div class="mbody">Falling back to wired ethernet. SSID <span class="mono">workshop-2g</span> last seen 53 min ago.</div>
+                  </div>
+                  <div class="mactions">
+                    <button class="mbtn">Network…</button>
+                    <button class="mbtn">Mute</button>
+                  </div>
+                </div>
+              </div>
+
+              <!-- Indicators sub-panel -->
+              <div class="indicators" data-sub="indicators">
+                <div class="ind">
+                  <div class="ind-label">Spindle Load</div>
+                  <div class="ind-val">0 %</div>
+                  <div class="ind-state"><span class="dot" style="background:#16a34a"></span> idle</div>
+                  <div class="progress"><div style="width:0%"></div></div>
+                </div>
+                <div class="ind">
+                  <div class="ind-label">Spindle Temp</div>
+                  <div class="ind-val">24 °C</div>
+                  <div class="ind-state"><span class="dot" style="background:#16a34a"></span> nominal</div>
+                  <div class="progress"><div style="width:24%"></div></div>
+                </div>
+                <div class="ind">
+                  <div class="ind-label">Driver Voltage</div>
+                  <div class="ind-val">48.1 V</div>
+                  <div class="ind-state"><span class="dot" style="background:#16a34a"></span> ok</div>
+                </div>
+                <div class="ind">
+                  <div class="ind-label">Coolant</div>
+                  <div class="ind-val">OFF</div>
+                  <div class="ind-state"><span class="dot" style="background:#94a3b8"></span> standby</div>
+                </div>
+
+                <div class="ind">
+                  <div class="ind-label">Limit X</div>
+                  <div class="ind-val" style="color:#16a34a">CLEAR</div>
+                  <div class="ind-state"><span class="dot" style="background:#16a34a"></span> ok</div>
+                </div>
+                <div class="ind">
+                  <div class="ind-label">Limit Y</div>
+                  <div class="ind-val" style="color:#16a34a">CLEAR</div>
+                  <div class="ind-state"><span class="dot" style="background:#16a34a"></span> ok</div>
+                </div>
+                <div class="ind">
+                  <div class="ind-label">Limit Z</div>
+                  <div class="ind-val" style="color:#dc2626">BLOCKED</div>
+                  <div class="ind-state"><span class="dot" style="background:#dc2626"></span> over-travel</div>
+                </div>
+                <div class="ind">
+                  <div class="ind-label">Probe</div>
+                  <div class="ind-val">OPEN</div>
+                  <div class="ind-state"><span class="dot" style="background:#94a3b8"></span> not contacted</div>
+                </div>
+
+                <div class="ind">
+                  <div class="ind-label">E-Stop</div>
+                  <div class="ind-val" style="color:#16a34a">RELEASED</div>
+                  <div class="ind-state"><span class="dot" style="background:#16a34a"></span> safe</div>
+                </div>
+                <div class="ind">
+                  <div class="ind-label">Door</div>
+                  <div class="ind-val">CLOSED</div>
+                  <div class="ind-state"><span class="dot" style="background:#16a34a"></span> ok</div>
+                </div>
+                <div class="ind">
+                  <div class="ind-label">Air Pressure</div>
+                  <div class="ind-val">6.2 bar</div>
+                  <div class="ind-state"><span class="dot" style="background:#16a34a"></span> ok</div>
+                  <div class="progress"><div style="width:62%"></div></div>
+                </div>
+                <div class="ind">
+                  <div class="ind-label">Vacuum</div>
+                  <div class="ind-val">−0.81 bar</div>
+                  <div class="ind-state"><span class="dot" style="background:#16a34a"></span> hold</div>
+                  <div class="progress"><div style="width:81%"></div></div>
+                </div>
+              </div>
+
+            </div>
+          </div>
+
+          <!-- ============= SETTINGS ============= -->
+          <div class="panel" data-panel="settings" style="padding:0;gap:0">
+            <div class="settings active" style="padding:18px">
+              <div class="set-side">
+                <div class="set-item active"><i class="fa-solid fa-display"></i> Display & Units</div>
+                <div class="set-item"><i class="fa-solid fa-arrows-up-down-left-right"></i> Motion</div>
+                <div class="set-item"><i class="fa-solid fa-bolt"></i> Spindle</div>
+                <div class="set-item"><i class="fa-solid fa-shield-halved"></i> Safety / Soft-limits</div>
+                <div class="set-item"><i class="fa-solid fa-network-wired"></i> Network</div>
+                <div class="set-item"><i class="fa-solid fa-video"></i> Camera</div>
+                <div class="set-item"><i class="fa-solid fa-keyboard"></i> Macros</div>
+                <div class="set-item"><i class="fa-solid fa-circle-info"></i> About</div>
+              </div>
+              <div class="set-content">
+                <div class="set-card">
+                  <div class="set-title">Display & Units</div>
+                  <div class="set-row">
+                    <div>
+                      <div class="label">Display Units</div>
+                      <div class="desc">Position, feed and dimensions throughout the UI.</div>
+                    </div>
+                    <div><div class="step-seg" style="display:inline-flex"><button class="active">METRIC</button><button>IMPERIAL</button></div></div>
+                    <div></div>
+                  </div>
+                  <div class="set-row">
+                    <div>
+                      <div class="label">Decimal places</div>
+                      <div class="desc">Position readout precision.</div>
+                    </div>
+                    <div><input class="set-input" value="3" /></div>
+                    <div class="val">0–4</div>
+                  </div>
+                  <div class="set-row">
+                    <div>
+                      <div class="label">Pulse-dot animation</div>
+                      <div class="desc">Animate status badges (ready, idle, alarm).</div>
+                    </div>
+                    <div><div class="set-toggle on"></div></div>
+                    <div></div>
+                  </div>
+                  <div class="set-row">
+                    <div>
+                      <div class="label">Theme</div>
+                      <div class="desc">Pick a tile finish.</div>
+                    </div>
+                    <div><span class="file-select"><i class="fa-solid fa-palette" style="color:#64748b"></i> V09 · Flat soft slate <i class="fa-solid fa-chevron-down caret"></i></span></div>
+                    <div></div>
+                  </div>
+                </div>
+
+                <div class="set-card">
+                  <div class="set-title">Network</div>
+                  <div class="set-row">
+                    <div>
+                      <div class="label">IP Address</div>
+                      <div class="desc">Wired ethernet, DHCP.</div>
+                    </div>
+                    <div><span class="mono" style="font-size:1.05rem;font-weight:700">10.1.10.55</span></div>
+                    <div><button class="mbtn">Edit</button></div>
+                  </div>
+                  <div class="set-row">
+                    <div>
+                      <div class="label">WiFi</div>
+                      <div class="desc">Wireless network connection.</div>
+                    </div>
+                    <div><span class="chip chip-red"><i class="fa-solid fa-wifi"></i> Not connected</span></div>
+                    <div><button class="mbtn primary">Configure</button></div>
+                  </div>
+                  <div class="set-row">
+                    <div>
+                      <div class="label">Hostname</div>
+                      <div class="desc">Used in mDNS / Bonjour discovery.</div>
+                    </div>
+                    <div><input class="set-input" value="onefinity-shop.local" style="width:300px" /></div>
+                    <div></div>
+                  </div>
+                </div>
+              </div>
+            </div>
+          </div>
+
+        </div>
+      </div>
+
+    </div>
+  </div>
+</div>
+
+</div>
+
+<script>
+  // ----- Build G-code list -----
+  const gcodeLines = [
+    [1,'G21','word'],[2,'; X = along blank, Z = tool entry from top, Y fixed','c'],
+    [3,'; Y fixed to blank center: 12.800','c'],[4,'; nominal rapid: 3200.0 mm/min','c'],
+    [5,'; stock top Z: -0.960','c'],[6,'; deepest allowed cut Z: -16.500','c'],
+    [7,'G21','word'],[8,'G90','word'],[9,'G0 Y12.800','word'],
+    [10,'G0 Z19.040','word'],[11,'; rough pass 1 radius=18.540','c'],
+    [12,'G0 X0.000','word'],[13,'G1 Z-0.710 F800.000','word cur'],
+    [14,'G1 Z-0.960 F200.000','word'],[15,'G4 P0.250','word'],
+    [16,'G1 X249.500 F200.000','word'],[17,'G4 P0.250','word'],
+    [18,'G0 Z19.040','word'],[19,'; rough pass 2 radius=17.540','c'],
+    [20,'G0 X0.000','word'],[21,'G1 Z-1.710 F800.000','word'],
+    [22,'G1 Z-1.960 F200.000','word'],[23,'G4 P0.250','word'],
+    [24,'G1 X249.500 F200.000','word'],[25,'G4 P0.250','word'],
+    [26,'G0 Z19.040','word'],[27,'; rough pass 3 radius=16.540','c'],
+    [28,'G0 X0.000','word'],[29,'G1 Z-2.710 F800.000','word'],
+    [30,'G1 Z-2.960 F200.000','word'],[31,'G4 P0.250','word'],
+    [32,'G1 X249.500 F200.000','word'],[33,'G4 P0.250','word'],
+    [34,'G0 Z19.040','word'],[35,'; rough pass 4 radius=15.540','c'],
+  ];
+  document.getElementById('gcode-list').innerHTML = gcodeLines.map(([n,t,cls])=>{
+    const isComment = cls.includes('c');
+    const isCur = cls.includes('cur');
+    const cls2 = 'gline' + (isCur?' cur':'');
+    const inner = isComment ? `<span class="gcomment">${t}</span>` : `<span class="gword">${t}</span>`;
+    return `<div class="${cls2}"><span class="gn">${n}</span><span>${inner}</span></div>`;
+  }).join('');
+
+  // ----- Top tab switching (Control / Program / Settings) -----
+  document.querySelectorAll('.ktab').forEach(b=>{
+    b.addEventListener('click', ()=>{
+      const target = b.dataset.target;
+      document.querySelectorAll('.ktab').forEach(x=>x.classList.remove('active'));
+      b.classList.add('active');
+      document.querySelectorAll('.panel').forEach(p=>p.classList.remove('active'));
+      document.querySelector(`.panel[data-panel="${target}"]`).classList.add('active');
+      applyScale();
+    });
+  });
+
+  // ----- Console sub-tab switching (MDI / Messages / Indicators) -----
+  function showSub(name){
+    document.querySelectorAll('.ptab').forEach(x=>x.classList.toggle('active', x.dataset.ptab===name));
+    document.querySelectorAll('[data-sub]').forEach(s=>{
+      const on = s.dataset.sub===name;
+      if(s.classList.contains('messages') || s.classList.contains('indicators') || s.classList.contains('mdi')){
+        s.classList.toggle('active', on);
+      }
+    });
+  }
+  document.querySelectorAll('.ptab').forEach(b=>{
+    b.addEventListener('click', ()=>{ showSub(b.dataset.ptab); });
+  });
+  // Default Console sub: MDI active
+  document.querySelectorAll('.messages[data-sub], .indicators[data-sub]').forEach(s=>s.classList.remove('active'));
+
+  // ----- Scaling -----
+  const stage = document.getElementById('stage');
+  const scaler = document.getElementById('scaler');
+  const viewport = document.getElementById('viewport');
+  const fitBtn = document.getElementById('fitBtn');
+  const oneToOne = document.getElementById('oneToOne');
+  const scaleInfo = document.getElementById('scaleInfo');
+  let mode = 'fit';
+  function activeKioskHeight(){
+    const m = document.querySelector('.kiosk');
+    return m ? Math.max(1080, m.offsetHeight) : 1080;
+  }
+  function applyScale(){
+    let s;
+    if(mode==='1:1'){
+      s = 1; scaleInfo.textContent = '100% · 1920px wide';
+    } else {
+      const sw = stage.clientWidth - 32;
+      s = Math.min(sw/1920, 1);
+      scaleInfo.textContent = Math.round(s*100) + '% · 1920px wide';
+    }
+    const h = activeKioskHeight();
+    scaler.style.transform = `scale(${s})`;
+    viewport.style.width  = (1920 * s) + 'px';
+    viewport.style.height = (h * s) + 'px';
+  }
+  window.addEventListener('resize', applyScale);
+  fitBtn.addEventListener('click', ()=>{ mode='fit'; fitBtn.classList.add('on'); oneToOne.classList.remove('on'); applyScale(); });
+  oneToOne.addEventListener('click', ()=>{ mode='1:1'; oneToOne.classList.add('on'); fitBtn.classList.remove('on'); applyScale(); });
+  applyScale();
+</script>
+</body>
+</html>

plans/2026-04-30_ux_redesign.md

@@ -0,0 +1,169 @@
+# UX Redesign — Implementation Plan
+
+Reference mock: `docs/mocks/v09_full_ux.html`
+Target hardware: 10.8" portable monitor, 1920×1080, capacitive touch, Chrome fullscreen.
+
+## 1. Goals
+
+The redesign keeps every existing feature but reorganizes the page into a single-screen control surface for finger-touch use:
+
+- A slim 96 px header replaces the 140 px nav-header. Only logo + ONEFINITY wordmark + tab bar + system pill + READY badge + octagonal STOP.
+- 4 top-level sections accessed via underline-ribbon tabs in the header:
+  1. **Control** — jog pad, DRO table, status strip, macro row.
+  2. **Program** — Auto run controls, file actions, G-code listing, 3D viewer.
+  3. **Console** — MDI, Messages, Indicators (sub-tabs).
+  4. **Settings** — paged settings (replaces the Pure left rail).
+- Touch targets ≥ 64 px (jog tiles 72 px, axis action icons 72 px, macro buttons 84 px).
+- All action chip-soup (WiFi/Camera/Rotary/IP/Version) collapses into one "All systems · view" pill that opens a popover. Burger menu removed (Settings tab supersedes it).
+- V09 jog/macro palette: flat soft slate (#3f4b63), no drop shadow; yellow (#fde047) accent for active states (step seg, tab underline, macro number badge).
+- Spindle override / feed override sliders live in a bottom-edge drawer triggered by tapping the Spindle KPI tile (no permanent screen real estate).
+- Hard cut: no `config.ui.layout` flag; the new shell replaces the old in a single release.
+
+## 2. Scope of code change
+
+The build is Pug + Stylus + Browserify Vue (Vue 1.x). `index.pug` defines the chrome; `src/pug/templates/*.pug` defines each view; `src/js/*.js` mirrors them as Vue components routed by `currentView` from the URL hash.
+
+Files we will touch:
+
+- `src/pug/index.pug` — replace `#layout / #menu / #main / .nav-header` with the new header + tab bar + body. Drop the burger and the side-menu include.
+- `src/pug/templates/control-view.pug` — restructure into the new Control panel (jog grid + DRO table + status strip + macro row). MDI/Messages/Indicators move out.
+- New `src/pug/templates/program-view.pug` — Auto sub-panel content (action bar, file bar, gcode-viewer, path-viewer).
+- New `src/pug/templates/console-view.pug` — MDI / Messages / Indicators sub-tabs hosting existing `console.pug` and `indicators.pug` partials.
+- `src/js/app.js` — extend `parse_hash` so `#program`, `#console`, `#settings` resolve; expose tab state for the header to highlight.
+- `src/js/control-view.js` — keep jog/DRO logic, drop the Auto/MDI/Messages/Indicators internal `tab` state and template hooks.
+- New `src/js/program-view.js`, `src/js/console-view.js` — extracted Vue components.
+- `src/stylus/style.styl` — add `.app-shell`, `.head`, `.tabs-host`, `.ktab`, panel styles, V09 jog tokens. Keep legacy classes alive until templates fully migrated.
+- `src/static/css/side-menu.css` — stop including in `index.pug`.
+- Settings: keep `settings-view.pug`, `admin-general-view.pug`, `admin-network-view.pug`, `motor-view.pug`, `tool-view.pug`, `io-view.pug`, etc., and surface them through a left-rail navigator inside the Settings panel rather than the sidebar.
+- Settings → Macros owns the full macro list (1…N). Control's macro row is a slice of the first 8; reordering happens in Settings.
+
+## 3. Routing model
+
+We keep the existing URL hash routing because everything in `src/js/app.js#parse_hash` and the deep-linked menu items (`#motor:0`, `#admin-network`, etc.) depend on it.
+
+| URL hash                | Top tab    | Notes                                                 |
+|-------------------------|------------|-------------------------------------------------------|
+| `#control`              | Control    | Default                                                |
+| `#program` / `#program:auto` | Program | Auto sub-view (only sub-view for now)                  |
+| `#console` / `#console:mdi`  | Console | MDI default, also `:messages` and `:indicators`        |
+| `#settings`             | Settings   | Settings home (Display & Units)                        |
+| `#admin-general`, `#admin-network`, `#motor:N`, `#tool`, `#io`, `#help`, `#cheat-sheet` | Settings | Existing routes remain, surfaced in the Settings left rail |
+
+The header tab bar maps URL prefix → active tab. A tiny helper `topTabFromHash(hash)` lives in `app.js` and is reused by the header template.
+
+## 4. Step-by-step
+
+### Phase 1 — Mock parity (1–2 days)
+1. Add `docs/mocks/v09_full_ux.html` (done) so anyone can preview the target.
+2. Move the V09 palette into Stylus tokens at the top of `style.styl`:
+   ```styl
+   $jog-bg     = #3f4b63
+   $jog-hover  = #4a5777
+   $jog-dir    = #5b6885
+   $jog-ghost  = #8c97ad
+   $accent     = #fde047
+   $accent-ink = #0f172a
+   ```
+3. Build the header in `index.pug`:
+   ```pug
+   .app-shell
+     header.head
+       .brand-blk
+         .brand-logo
+         .brand-name ONEFINITY
+       nav.tabs-host(role="tablist")
+         a.ktab(:class="{active: topTab === 'control'}", href="#control")
+           .fa.fa-gamepad
+           | Control
+         a.ktab(:class="{active: topTab === 'program'}", href="#program") …
+         a.ktab(:class="{active: topTab === 'console'}", href="#console") …
+         a.ktab(:class="{active: topTab === 'settings'}", href="#settings") …
+       button.sys-btn(@click="toggle_sys_popover") …
+       span.state-badge(:class="state_class")
+       estop(@click="estop")
+   ```
+4. Style the header tabs as **underline ribbon** (V02): transparent fills, slate-gray text, dark text + 5 px yellow underline on active. CSS already proven in the mock.
+5. Move the rotary toggle and pi-temp warning into the system pill popover.
+
+### Phase 2 — Control panel (2 days)
+1. Rewrite the outer markup of `control-view.pug` to a CSS grid:
+   ```
+   .control-grid → 720px jog-card | 1fr right-col(dro-card + status-strip)
+   ```
+   Drop the `<table>`-based outer layout (axes table stays — it's a real data table).
+2. Replace the legacy `<button>` elements in the jog table with `.jbtn` markup that pulls colors from `$jog-*` tokens. Keep the `@click="jog_fn(...)"` bindings unchanged.
+3. Build the new `.step-seg` with the existing `jog_incr` model. The four buttons stay wired to `jog_incr = 'fine' | 'small' | 'medium' | 'large'`.
+4. Build `.dro-card` from the existing `table.axes` markup. Each row gets the new 7-column grid; axis cells just need `.dro-axis`, `.dro-pos`, `.dro-sec` classes.
+5. Move the four KPI tiles (`State / Velocity-Feed / Spindle / Job`) into `.status-strip`. Existing `state.v`, `state.feed`, `state.s`, `state.line` bindings are unchanged.
+6. Move `.macros-div` into a `.macro-row` 8-column grid. The row binds to `config.macros.slice(0, 8)`; macros 9…N are editable and runnable only from Settings → Macros (no drawer in Control). Reordering in Settings changes which macros appear in the visible 8.
+7. Drop the legacy `.tabs / #tab1 …` block from `control-view.pug` entirely.
+
+### Phase 3 — Program panel (1.5 days)
+1. New file `src/pug/templates/program-view.pug` with `.program-card` and the action / file bars.
+2. Move the Auto bar (RUN, STOP, UPLOAD FOLDER, UPLOAD FILE, DOWNLOAD FILE, DELETE) and the file-select strip (Create Folder, Delete Folder, folder picker, file picker, sort) out of `control-view.pug` into here. Use the V09 button styles (`.action-btn`, `.action-btn.run`, `.action-btn.danger`, `.file-btn`, `.file-select`).
+3. Embed `path-viewer` and `gcode-viewer` in `.program-body { 1fr 600px }`. Both Vue components render unchanged.
+4. New `src/js/program-view.js` exporting the same data model the existing `Auto` tab uses (`gcode_files`, `state.selected`, `start_pause`, etc.). The fastest path: move the relevant computed/methods into a mixin `gcode-program-mixin.js` consumed by both old and new components during the migration.
+5. Wire `<component :is="currentView + '-view'">` in `index.pug` to pick up `program-view`.
+
+### Phase 4 — Console panel (1 day)
+1. New `src/pug/templates/console-view.pug` with the inner `.ptab-bar` (MDI / Messages / Indicators) and `data-sub` panels.
+2. The MDI panel reuses the existing `<input v-model="mdi" @keyup.enter="submit_mdi">` plus the on-screen keypad (G0/G1/G2/G3/G28/G92/M3/M5 + axis letters + CLEAR/SEND).
+3. The Messages panel pulls from the existing `popupMessages` array + a new `messages_log` state we will accumulate from `app.js`'s `error` and `popupMessages` channels (no protocol change).
+4. The Indicators panel mounts the existing `<indicators :state="state" :template="template">` component.
+5. Sub-tab state is local Vue state (`activeSub: 'mdi' | 'messages' | 'indicators'`) plus URL fragment after `:` so deep links keep working.
+
+### Phase 5 — Settings panel (1 day)
+1. New `src/pug/templates/settings-view.pug` with a left rail and a content slot.
+2. The left rail is data-driven from a list of existing settings views: General, Network, Motion (settings-view), Spindle (tool-view), Safety (admin-general subset), Camera, Macros (settings-view subset), I/O, Motors, Help, About.
+3. The content slot uses `<component :is="settingsSub + '-view'">` so each existing pug template renders unchanged (`admin-general-view.pug`, `admin-network-view.pug`, `motor-view.pug`, `tool-view.pug`, `io-view.pug`, `settings-view.pug`, `help-view.pug`, `cheat-sheet-view.pug`).
+4. Existing routes (`#admin-network`, `#motor:0`, …) resolve to Settings + the matching left-rail item. We lose nothing.
+5. Decommission the side menu in `index.pug` and stop including `side-menu.css`.
+
+### Phase 6 — Polish & rollout (0.5 days)
+1. Pulse-dot animation for the READY badge (CSS keyframes already in the mock).
+2. System pill popover content: WiFi state + button, Camera state + retry, Rotary toggle, IP address, firmware version, "Open Settings".
+3. Disabled states: jog buttons + macro buttons honor `is_ready` like before; gray them out instead of hiding.
+4. Decimal-places setting from the existing `display_units` plumbing — wire to a new `precision` config the DRO reads.
+5. Build the **Spindle override drawer**: clicking the `.stat-card` for Spindle toggles `.override-drawer.open` anchored to the bottom edge of the body. The drawer hosts the two existing `<input type="range">` controls for `feed_override` and `speed_override` plus `Reset` buttons. Bind to the existing `override_feed` / `override_speed` methods.
+6. **Hard cut cleanup:** delete the legacy `.nav-header`, side-menu markup, and the inline `.tabs / #tab1…#tab4` block from `control-view.pug`. Remove `src/static/css/side-menu.css` from `index.pug` includes. Sweep `style.styl` for orphan rules (`.nav-header`, `.brand`, `.menu-link`, `.pure-menu*` overrides, `.tabs > input` selectors) and delete them in the same commit so we don't ship dead CSS.
+
+## 5. Migration risks & mitigations
+
+| Risk                                         | Mitigation                                                                                  |
+|----------------------------------------------|---------------------------------------------------------------------------------------------|
+| Existing deep links from PDFs / forum posts (`#admin-network`) break | Keep the same hashes; only their visual shell changes. `parse_hash` resolves them. |
+| Vue 1.x doesn't support modern slot syntax we used in the mock | The mock is plain HTML for visual review; production code uses the existing Vue 1 patterns. No new Vue features required. |
+| Touch monitor with HDMI vs USB-C may report different DPI | The new layout is fluid inside 1920 × 1080 only when fullscreen Chrome. Provide a CSS `@media (max-width: 1820px)` fallback that scales the macro row to 4 columns and stacks the right column under the jog. |
+| Existing customers rely on muscle memory of the side menu | Settings tab opens directly to the same left-rail navigator. First-launch toast: "Side menu moved to Settings." |
+| `path-viewer` / `gcode-viewer` are heavy three.js components | They live in the Program tab now; we lazy-mount with `v-if="currentView === 'program'"` so Control stays light. |
+| MDI input could lose focus when the inner `.ptab` is switched | Keep the input mounted, just hide non-active subs with `display:none`. |
+
+## 6. Testing checklist
+
+- Chrome on the 10.8" 1920 × 1080 monitor, fullscreen — every panel fits without scrolling at 100 %.
+- Chrome at 1366 × 768 — fallback layout works (Control collapses jog above DRO).
+- Touch hit-tests: every interactive target ≥ 48 px on its shortest side, primary jog tiles ≥ 72 px.
+- Existing flows still work end-to-end: home all axes, run a small program, MDI a `G0 X10`, switch to Imperial, upload a folder, delete a file.
+- Hash routing: hand-type `#motor:1` and confirm Settings tab activates with Motor 1 selected.
+- Spindle override drawer: tap Spindle KPI tile, sliders move feed/speed override, `Reset` returns both to 100 %, tile tap closes drawer.
+- Macro row shows macros 1–8 only; reordering in Settings → Macros changes which 8 appear on Control.
+- Pulse-dot animation respects `prefers-reduced-motion`.
+- Hard-cut cleanup verified: `git grep` finds no references to the old `.nav-header`, `side-menu.css`, or the `#tab1…#tab4` selectors after the rename.
+
+## 7. Estimated effort
+
+About 6–7 working days for one developer:
+
+1. Mock parity & header — 1.5 days
+2. Control panel (incl. macro slice + DRO grid) — 2 days
+3. Program panel — 1.5 days
+4. Console panel — 1 day
+5. Settings shell — 1 day
+6. Override drawer, polish, hard-cut cleanup, regression tests — 0.5–1 day
+
+## 8. Resolved decisions
+
+- **Rollout: hard cut.** No `config.ui.layout` feature flag, no parallel legacy shell. The new `index.pug` tree replaces the old one in a single release; the old `.nav-header`, side menu, and embedded `.tabs` block are deleted (not gated). One pre-release internal QA pass on real hardware before tagging.
+- **Macros above 8: Settings owns the master list; Control surfaces the first 8 (configurable).** The Control macro row reads from `config.macros[0..7]`; everything beyond index 7 is editable / runnable only from Settings → Macros. Users can reorder which macros land in the visible 8 there.
+- **"Pin to Control" indicator slot: defer.** Not in this redesign. Tracked as a follow-up; current status strip stays fixed at State / Velocity·Feed / Spindle / Job.
+- **Feed & spindle override: drawer triggered by the Spindle KPI tile.** The Spindle card in the status strip becomes tappable. Tap opens a bottom-edge drawer (≈ 220 px tall) containing the two existing range inputs (`feed_override`, `speed_override`) at touch-friendly size with `Reset to 100 %` buttons. Closes by tapping the tile again or the drawer chevron. No protocol change; reuses the existing `override_feed` / `override_speed` handlers.

scripts/bbctrl.service

@@ -1,13 +1,24 @@
 [Unit]
 Description=Buildbotics Controller
-After=network.target
+# Note: bbctrl previously had `After=network.target`. That delays
+# start by ~5s on this Pi while dhcpcd brings up wlan0/eth0, but
+# bbctrl does not actually require network connectivity to come up
+# (the AVR is on a local serial port, the LCD on I2C). Dropping it
+# means the Pi shows the UI faster on cold boot. The wifi config UI
+# still works because it queries iw/dhcpcd lazily on demand.
+After=local-fs.target bbserial-rebind.service
+Wants=bbserial-rebind.service
 
 [Service]
 User=root
 ExecStart=/usr/local/bin/bbctrl -l /var/log/bbctrl.log
 WorkingDirectory=/var/lib/bbctrl
 Restart=always
-StandardOutput=null
+# StandardOutput was 'null'. Set to 'journal' so TRACE lines emitted by
+# bbctrl.Trace are visible via `journalctl -u bbctrl`. Bbctrl still
+# writes its own log via -l above; this only affects stdout/stderr.
+StandardOutput=journal
+StandardError=journal
 Nice=-10
 KillMode=process
 

scripts/bbserial-rebind.service

@@ -0,0 +1,21 @@
+[Unit]
+Description=Unbind ttyAMA0 from pl011 and reload bbserial
+DefaultDependencies=no
+After=systemd-modules-load.service local-fs.target
+Before=bbctrl.service
+ConditionPathExists=/sys/bus/amba/drivers/uart-pl011
+
+[Service]
+Type=oneshot
+RemainAfterExit=yes
+# Tolerate the device already being bound elsewhere or the module
+# already being loaded — the goal is the end state (bbserial owns
+# ttyAMA0), not running the steps.
+ExecStart=/bin/sh -c '\
+    echo 3f201000.serial > /sys/bus/amba/drivers/uart-pl011/unbind 2>/dev/null || true; \
+    /sbin/modprobe -r bbserial 2>/dev/null || true; \
+    /sbin/modprobe bbserial \
+'
+
+[Install]
+WantedBy=multi-user.target

scripts/deploy/hardware.sh

@@ -0,0 +1,84 @@
+#!/bin/bash
+# --- Hardware iteration (live Pi at onefinity.local) ---
+#
+# Rsyncs the freshly built static UI tree (build/http/) onto the Pi's
+# bbctrl egg directory and restarts bbctrl. This is much faster than
+# a full firmware update and is the fastest way to iterate on the V09
+# UI changes against real machine state (W axis, jog feedback, etc).
+#
+# Defaults:
+#   HOST=onefinity.local
+#   REMOTE_USER=bbmc
+#   PASSWORD=onefinity      (used for sudo on the Pi)
+#
+# Override:
+#   HOST=10.1.10.55 ./deploy.sh hardware
+
+set -euo pipefail
+
+SCRIPT_DIR="$(cd "$(dirname "${BASH_SOURCE[0]}")/../.." && pwd)"
+cd "$SCRIPT_DIR"
+
+HOST="${HOST:-onefinity.local}"
+REMOTE_USER="${REMOTE_USER:-bbmc}"
+PASSWORD="${PASSWORD:-onefinity}"
+
+echo "Building UI bundle (HTML + resources)..."
+make build/http/index.html >/dev/null
+# Copy src/resources/* into build/http/. The Makefile's "all" target
+# also does this, but pulls in cross-compiled subprojects (avr/boot/
+# pwr/jig) we don't have toolchains for on macOS. This rsync mirrors
+# only the resource tree.
+rsync -a src/resources/ build/http/
+
+echo "Locating bbctrl http/ directory on $HOST..."
+REMOTE_HTTP_DIR="$(ssh -o ConnectTimeout=5 "${REMOTE_USER}@${HOST}" \
+  "ls -d /usr/local/lib/python*/dist-packages/bbctrl-*-py*.egg/bbctrl/http 2>/dev/null | head -1")"
+if [[ -z "$REMOTE_HTTP_DIR" ]]; then
+    echo "ERROR: could not find bbctrl http/ directory on $HOST"
+    exit 1
+fi
+echo "  $REMOTE_HTTP_DIR"
+
+echo "Rsyncing build/http/ -> $HOST:$REMOTE_HTTP_DIR/"
+# Stage to a tmp dir owned by $REMOTE_USER, then sudo-rsync into
+# place. This avoids needing root over rsync. We do NOT use --delete
+# anywhere -- the Pi's egg ships extra runtime files (config-template
+# .json, default machine JSON, buildbotics.nc, etc.) that come with
+# the bbctrl package and are not in this repo's src/resources. If
+# they were deleted the controller's API would 500 because Python
+# imports fail.
+REMOTE_TMP="/tmp/onefin_ui_$$"
+ssh -o ConnectTimeout=5 "${REMOTE_USER}@${HOST}" "mkdir -p '${REMOTE_TMP}'"
+rsync -avz \
+  --exclude='hostinfo.txt' \
+  -e "ssh -o ConnectTimeout=5" \
+  build/http/ "${REMOTE_USER}@${HOST}:${REMOTE_TMP}/"
+
+echo "Installing into ${REMOTE_HTTP_DIR}/ (sudo)..."
+ssh -o ConnectTimeout=5 "${REMOTE_USER}@${HOST}" \
+  "echo '${PASSWORD}' | sudo -S bash -c '
+     rsync -a --exclude=hostinfo.txt \"${REMOTE_TMP}/\" \"${REMOTE_HTTP_DIR}/\" \
+       && rm -rf \"${REMOTE_TMP}\"
+   '" 2>&1 | tail -3
+
+# Patch bbctrl Web.py so font files get the correct MIME type. The
+# Pi ships Python 3.5, whose `mimetypes` module doesn't know about
+# woff/woff2/ttf, so Tornado serves them as application/octet-stream
+# which Chromium 72 (the Pi's onboard browser) refuses to use as a
+# web font, leading to all FontAwesome icons rendering as empty
+# boxes in the kiosk UI. The patch is idempotent.
+echo "Patching bbctrl font MIME types (idempotent)..."
+scp -o ConnectTimeout=5 "$SCRIPT_DIR/scripts/deploy/patch_font_mime.py" \
+  "${REMOTE_USER}@${HOST}:/tmp/patch_font_mime.py" >/dev/null
+ssh -o ConnectTimeout=5 "${REMOTE_USER}@${HOST}" \
+  "echo '${PASSWORD}' | sudo -S python3 /tmp/patch_font_mime.py" 2>&1 | tail -3
+
+echo "Restarting bbctrl service..."
+ssh -o ConnectTimeout=5 "${REMOTE_USER}@${HOST}" \
+  "echo '${PASSWORD}' | sudo -S systemctl restart bbctrl" 2>&1 | tail -3
+
+echo ""
+echo "Deployed to http://${HOST}/"
+echo "  Logs: ssh ${REMOTE_USER}@${HOST} 'journalctl -u bbctrl -f'"
+echo "  Open: open -a 'Google Chrome' http://${HOST}/"

scripts/deploy/local.sh

@@ -0,0 +1,75 @@
+#!/bin/bash
+# --- Local development (macOS) ---
+#
+# Builds the UI bundle and static-serves it on http://localhost:8770/.
+# Runs in a named tmux session so we can iterate (re-running this script
+# rebuilds and restarts the server in-place, you keep your browser tab).
+#
+# What you'll see:
+#   * The full V09 chrome (header tabs, settings rail, jog grid, DRO
+#     skeleton, status strip).
+#   * A "DISCONNECTED" overlay because there's no controller backend.
+#   * The W axis row in jog/DRO is hidden (correct: it appears only when
+#     the controller reports `aux_enabled = true`). To exercise the W
+#     axis end-to-end, deploy to the Pi (`./deploy.sh hardware`).
+
+set -euo pipefail
+
+SCRIPT_DIR="$(cd "$(dirname "${BASH_SOURCE[0]}")/../.." && pwd)"
+cd "$SCRIPT_DIR"
+
+echo "🛠  Building UI bundle..."
+make build/http/index.html >/dev/null
+
+PORT="${PORT:-8770}"
+SESSION="onefin-local"
+
+ensure_tmux_window() {
+    local session="$1"
+    local window="${2:-}"
+    local target="${session}${window:+:$window}"
+    if tmux has-session -t "$session" 2>/dev/null; then
+        if tmux send-keys -t "$target" "" 2>/dev/null; then
+            echo "🔁 Reusing tmux session '$session'..."
+            tmux send-keys -t "$target" C-c
+            sleep 1
+            return
+        fi
+        echo "⚠️  Dead pane in '$session', recreating..."
+        tmux kill-session -t "$session" 2>/dev/null
+    fi
+    echo "🆕 Creating tmux session '$session'..."
+    tmux new-session -d -s "$session"
+}
+
+ensure_tmux_window "$SESSION"
+
+# Free the port if a previous run is still listening.
+if lsof -iTCP:"$PORT" -sTCP:LISTEN >/dev/null 2>&1; then
+    echo "⚠️  Port $PORT is busy; killing previous server..."
+    lsof -tiTCP:"$PORT" -sTCP:LISTEN | xargs -r kill 2>/dev/null || true
+    sleep 1
+fi
+
+tmux send-keys -t "$SESSION" \
+  "cd '$SCRIPT_DIR' && python3 -m http.server --directory build/http $PORT" \
+  C-m
+
+echo ""
+echo "✅ Static UI server started on http://localhost:$PORT/"
+echo ""
+echo "   Routes to try:"
+echo "     http://localhost:$PORT/#control"
+echo "     http://localhost:$PORT/#program"
+echo "     http://localhost:$PORT/#console"
+echo "     http://localhost:$PORT/#settings        (Display & Units)"
+echo "     http://localhost:$PORT/#admin-network   (WiFi / IP)"
+echo "     http://localhost:$PORT/#motor:0         (Motor 0 settings)"
+echo ""
+echo "   tmux:        tmux attach -t $SESSION"
+echo "   stop:        tmux kill-session -t $SESSION"
+echo ""
+echo "ℹ️  No controller is running, so the page shows DISCONNECTED and"
+echo "   axis values stay empty. For live data + W axis, run:"
+echo "     ./deploy.sh hardware     (fast: rsync build/http -> Pi)"
+echo "     ./deploy.sh prod         (full firmware update)"

scripts/deploy/patch_font_mime.py

@@ -0,0 +1,102 @@
+#!/usr/bin/env python3
+"""
+Patch bbctrl Web.py so font files get the correct MIME type.
+
+Background
+----------
+The Onefinity controller (Pi 3B running Raspbian stretch) ships Python
+3.5, whose ``mimetypes`` module does not recognize ``.woff``, ``.woff2``
+or ``.ttf``. Tornado's ``StaticFileHandler`` therefore falls back to
+``application/octet-stream`` for those, and Chromium 72 (the Pi's
+onboard kiosk browser) refuses to use such payloads as web fonts. The
+result is that every FontAwesome icon renders as an empty box on the
+kiosk display.
+
+This patch monkey-patches ``StaticFileHandler.get_content_type`` to
+emit the right MIME types. It is idempotent: running it twice is a
+no-op. Run with ``sudo`` so it can rewrite the egg's Web.py.
+
+Used by:
+  scripts/deploy/hardware.sh
+"""
+
+from __future__ import print_function
+import os
+import sys
+
+
+def find_web_py():
+    """Return the absolute path to the bbctrl Web.py shipped in the egg."""
+    base = "/usr/local/lib"
+    for entry in os.listdir(base):
+        if not entry.startswith("python"):
+            continue
+        candidate_dir = os.path.join(base, entry, "dist-packages")
+        if not os.path.isdir(candidate_dir):
+            continue
+        for sub in os.listdir(candidate_dir):
+            if sub.startswith("bbctrl-") and sub.endswith(".egg"):
+                p = os.path.join(candidate_dir, sub, "bbctrl", "Web.py")
+                if os.path.isfile(p):
+                    return p
+    return None
+
+
+OLD_BLOCK = (
+    "class StaticFileHandler(tornado.web.StaticFileHandler):\n"
+    "    def set_extra_headers(self, path):\n"
+    "        self.set_header('Cache-Control',\n"
+    "                        'no-store, no-cache, must-revalidate, max-age=0')"
+)
+
+NEW_BLOCK = (
+    "class StaticFileHandler(tornado.web.StaticFileHandler):\n"
+    "    # FONT_MIME_FIX: Python 3.5's mimetypes module does not know\n"
+    "    # woff/woff2/ttf, so Tornado serves them as application/octet-\n"
+    "    # stream which Chromium 72 (the Pi's onboard kiosk browser)\n"
+    "    # refuses to use as web fonts. Set explicit types so the FA6\n"
+    "    # icon set actually renders on the kiosk display.\n"
+    "    def get_content_type(self):\n"
+    "        path = self.absolute_path or ''\n"
+    "        if path.endswith('.woff2'): return 'font/woff2'\n"
+    "        if path.endswith('.woff'):  return 'font/woff'\n"
+    "        if path.endswith('.ttf'):   return 'font/ttf'\n"
+    "        if path.endswith('.otf'):   return 'font/otf'\n"
+    "        if path.endswith('.eot'):   return 'application/vnd.ms-fontobject'\n"
+    "        return super().get_content_type()\n"
+    "\n"
+    "    def set_extra_headers(self, path):\n"
+    "        self.set_header('Cache-Control',\n"
+    "                        'no-store, no-cache, must-revalidate, max-age=0')"
+)
+
+
+def main():
+    target = find_web_py()
+    if target is None:
+        print("ERROR: could not locate bbctrl Web.py under /usr/local/lib",
+              file=sys.stderr)
+        return 1
+
+    with open(target) as f:
+        src = f.read()
+
+    if "FONT_MIME_FIX" in src:
+        print("font mime: already patched ({})".format(target))
+        return 0
+
+    if OLD_BLOCK not in src:
+        print("font mime: expected block not found in {} -- skipping".format(target),
+              file=sys.stderr)
+        # Don't fail the deploy; just log and continue.
+        return 0
+
+    new_src = src.replace(OLD_BLOCK, NEW_BLOCK, 1)
+    with open(target, "w") as f:
+        f.write(new_src)
+    print("font mime: patched {}".format(target))
+    return 0
+
+
+if __name__ == "__main__":
+    sys.exit(main())

scripts/deploy/prod.sh

@@ -0,0 +1,42 @@
+#!/bin/bash
+# --- Production firmware update (Pi at onefinity.local) ---
+#
+# Builds a full firmware package (.tar.bz2) and PUTs it through the Pi's
+# /api/firmware/update endpoint. This is the canonical OTA flow and goes
+# through the bbctrl Tornado server's update handler.
+#
+# Defaults:
+#   HOST=onefinity.local
+#   PASSWORD=onefinity
+#
+# Override:
+#   HOST=10.1.10.55 PASSWORD=secret ./deploy.sh prod
+
+set -euo pipefail
+
+SCRIPT_DIR="$(cd "$(dirname "${BASH_SOURCE[0]}")/../.." && pwd)"
+cd "$SCRIPT_DIR"
+
+HOST="${HOST:-onefinity.local}"
+PASSWORD="${PASSWORD:-onefinity}"
+
+# Require a clean working tree.
+echo "🔍 Checking git state..."
+if ! git diff --quiet || ! git diff --cached --quiet \
+    || [[ -n "$(git ls-files --others --exclude-standard)" ]]; then
+    echo "❌ Refusing to deploy: working tree has uncommitted changes."
+    git status --short
+    exit 1
+fi
+echo "✅ Working tree is clean."
+
+echo "🛠  Building firmware package..."
+make pkg
+
+echo "🚚 Uploading to http://${HOST}/api/firmware/update..."
+make update HOST="$HOST" PASSWORD="$PASSWORD"
+
+echo ""
+echo "✅ Firmware update PUT to ${HOST}."
+echo "   The Pi will reboot itself after applying the update."
+echo "   Once it comes back, open: http://${HOST}/"

scripts/install.sh

@@ -19,8 +19,17 @@ if $UPDATE_PY; then
     # Update service
     rm -f /etc/init.d/bbctrl
     cp scripts/bbctrl.service /etc/systemd/system/
+
+    # Cold-boot fast path:
+    #   - bbserial-rebind.service replaces the bbserial unbind/reload
+    #     that used to live in rc.local AFTER bbctrl was already
+    #     listening on /dev/ttyAMA0. Doing it as a unit ordered
+    #     Before=bbctrl.service eliminates a full bbctrl restart
+    #     mid-boot (~5s saved).
+    cp scripts/bbserial-rebind.service /etc/systemd/system/
     systemctl daemon-reload
     systemctl enable bbctrl
+    systemctl enable bbserial-rebind.service
 fi
 
 if $UPDATE_AVR; then
@@ -118,8 +127,50 @@ if [ $? -ne 0 ]; then
     REBOOT=true
 fi
 
-# Install rc.local
-cp scripts/rc.local /etc/
+# Install rc.local. Use the slimmed "fast" variant if it exists in this
+# checkout (preferred); fall back to the legacy rc.local for older
+# firmware tarballs that don't ship rc.local.fast yet.
+if [ -f scripts/rc.local.fast ]; then
+    cp scripts/rc.local.fast /etc/rc.local
+else
+    cp scripts/rc.local /etc/rc.local
+fi
+chmod +x /etc/rc.local
+
+# Cold-boot: mask units that contribute to userspace startup time but
+# do not benefit a deployed Onefinity Pi. Each is reversible with
+# `systemctl unmask <unit>`.
+#   plymouth-read-write : 4s of work for a splash that rc.local kills
+#                         immediately with `plymouth quit`.
+#   plymouth-quit-wait  : holds graphical.target until the splash is
+#                         fully gone; redundant once the splash is
+#                         masked.
+#   raspi-config        : one-shot first-boot config; on a deployed
+#                         image it's a 2s no-op.
+#   sysstat             : sadc CPU/IO stats logger; not used.
+# Use --now so the change also applies to the running system; harmless
+# on a fresh install where the units are inactive.
+for unit in \
+    plymouth-read-write.service \
+    plymouth-quit-wait.service \
+    raspi-config.service \
+    sysstat.service; do
+    systemctl mask --now "$unit" 2>/dev/null || true
+done
+
+# Cold-boot: switch swap activation from dphys-swapfile (~4.3s LSB
+# wrapper that re-checks the swap file size on every boot) to a plain
+# fstab entry. The swap file itself is already created at
+# /var/swap by the previous boot; we only need to make sure it gets
+# `swapon`'d at local-fs.target instead.
+SWAPFILE=/var/swap
+if [ -f "$SWAPFILE" ]; then
+    if ! grep -qE "^[^#]*${SWAPFILE//\//\\/}[[:space:]]+swap" /etc/fstab; then
+        echo "$SWAPFILE none swap sw 0 0" >> /etc/fstab
+    fi
+    systemctl mask --now dphys-swapfile.service 2>/dev/null || true
+    swapon -a 2>/dev/null || true
+fi
 
 # Ensure that the watchdog python library is installed
 pip3 list --format=columns | grep watchdog >/dev/null

scripts/rc.local

@@ -28,4 +28,4 @@ plymouth quit
 
 # Start X in /home/pi
 cd /home/pi
-sudo -u pi startx
+sudo -u pi startx -- -nocursor

scripts/rc.local.fast

@@ -0,0 +1,42 @@
+#!/bin/bash
+# rc.local for the OneFinity Pi, "fast" variant.
+#
+# What changed vs. scripts/rc.local:
+#   - bbserial unbind/rebind moved to bbserial-rebind.service (runs
+#     once, before bbctrl, instead of after bbctrl is already
+#     listening on the serial port).
+#   - startx moved to kiosk.service so chromium starts in parallel
+#     with bbctrl rather than blocking on rc.local.
+#   - rc.local no longer keeps the Pi in 'starting' state forever,
+#     which fixes systemd-analyze.
+
+set -e
+
+# Mount /boot read only
+mount -o remount,ro /boot 2>/dev/null || true
+
+# Set SPI GPIO mode
+gpio mode 27 alt3 || true
+
+# Create browser memory limited cgroup
+if [ -d /sys/fs/cgroup/memory ]; then
+    CGROUP=/sys/fs/cgroup/memory/chrome
+    [ -d "$CGROUP" ] || mkdir -p "$CGROUP"
+    chown -R pi:pi "$CGROUP"
+    echo 650000000 > "$CGROUP/memory.soft_limit_in_bytes"
+    echo 750000000 > "$CGROUP/memory.limit_in_bytes"
+fi
+
+# Stop boot splash; harmless if plymouth already gone.
+plymouth quit 2>/dev/null || true
+
+# Start X (chromium kiosk) in the background so rc.local can exit and
+# late-boot units (bbctrl logrotate, etc.) don't block on it. Output
+# is redirected so the journal doesn't fill up with X warnings.
+cd /home/pi
+# `-- -nocursor` hides the X pointer; this is a touchscreen kiosk and
+# the mouse cursor only gets in the way.
+nohup sudo -u pi startx -- -nocursor >/var/log/onefin-x.log 2>&1 &
+disown
+
+exit 0

scripts/setup_rpi.sh

@@ -75,7 +75,7 @@ sed -i 's/^PARTUUID=.*\//\/dev\/mmcblk0p2 \//' /etc/fstab
 
 # Enable browser in xorg
 sed -i 's/allowed_users=console/allowed_users=anybody/' /etc/X11/Xwrapper.config
-echo "sudo -u pi startx" >> /etc/rc.local
+echo "sudo -u pi startx -- -nocursor" >> /etc/rc.local
 cp /mnt/host/xinitrc /home/pi/.xinitrc
 cp /mnt/host/ratpoisonrc /home/pi/.ratpoisonrc
 cp /mnt/host/xorg.conf /etc/X11/

setup.py

@@ -17,7 +17,7 @@ setup(
     license = pkg['license'],
     url = pkg['homepage'],
     package_dir = {'': 'src/py'},
-    packages = ['bbctrl', 'inevent', 'lcd', 'camotics','iw_parse'],
+    packages = ['bbctrl', 'inevent', 'lcd', 'camotics', 'iw_parse'],
     include_package_data = True,
     entry_points = {
         'console_scripts': [

src/js/a-axis-view.js

@@ -0,0 +1,20 @@
+"use strict";
+
+// V09 A-axis page — mounts the AAxisSettings Svelte component
+// inside the settings shell so it gets a real top-level rail entry
+// instead of being a soft-link anchor inside Display & Units.
+
+module.exports = {
+    template: "#a-axis-view-template",
+
+    attached: function () {
+        this.svelteComponent = SvelteComponents.createComponent(
+            "AAxisSettings",
+            document.getElementById("a-axis-mount")
+        );
+    },
+
+    detached: function () {
+        if (this.svelteComponent) this.svelteComponent.$destroy();
+    },
+};

src/js/app.js

@@ -4,6 +4,7 @@ const api = require("./api");
 const cookie = require("./cookie")("bbctrl-");
 const Sock = require("./sock");
 const semverLt = require("semver/functions/lt");
+const restartTiming = require("./restart-timing");
 
 if (document.getElementById("svelte-dialog-host") != undefined) {
   SvelteComponents.createComponent(
@@ -103,12 +104,23 @@ module.exports = new Vue({
         return {
           status: "connecting",
           currentView: "loading",
+          // Top-level shell tab. Mapped from the URL hash by parse_hash().
+          // One of: control | program | console | settings
+          top_tab: "control",
+          // Sub-route when a tab has internal pages (e.g. console:mdi,
+          // settings:admin-network, settings:motor:0). The settings sub
+          // also drives which inner view is mounted.
+          sub_tab: "",
+          sys_open: false,
+          has_camera: true,
+          messages_log: [],
+          messages_seen: 0,
           display_units: localStorage.getItem("display_units") || "METRIC",
           index: -1,
           modified: false,
           template: require("../resources/config-template.json"),
           config: {
-            settings: { 
+            settings: {
               units: "METRIC",
               "easy-adapter": false
             },
@@ -143,22 +155,15 @@ module.exports = new Vue({
         estop: { template: "#estop-template" },
         "loading-view": { template: "<h1>Loading...</h1>" },
         "control-view": require("./control-view"),
-        "settings-view": require("./settings-view"),
-        "motor-view": require("./motor-view"),
-        "tool-view": require("./tool-view"),
-        "io-view": require("./io-view"),
-        "admin-general-view": require("./admin-general-view"),
-        "admin-network-view": require("./admin-network-view"),
-        "macros-view": require('./macros'),
-        "help-view": require("./help-view"),
-        "cheat-sheet-view": {
-            template: "#cheat-sheet-view-template",
-            data: function() {
-                return {
-                    showUnimplemented: false
-                };
-            },
-        },
+        "program-view": require("./program-view"),
+        "console-view": require("./console-view"),
+
+        // The settings-shell renders the rail + an inner routed view.
+        // All settings-family hashes (settings, admin-general,
+        // admin-network, motor:N, tool, io, macros, help, cheat-sheet)
+        // resolve to this same shell; parse_hash() sets sub_tab so the
+        // shell knows which inner template to mount.
+        "settings-shell-view": require("./settings-shell-view"),
     },
 
     watch: {
@@ -166,6 +171,25 @@ module.exports = new Vue({
             localStorage.setItem("display_units", value);
             SvelteComponents.setDisplayUnits(value);
         },
+
+        // Mirror controller messages into a console log used by the
+        // Console > Messages tab and the header badge counter.
+        "state.messages": {
+            handler: function(messages) {
+                if (!Array.isArray(messages)) return;
+                this.messages_log = messages.map(m => ({
+                    text: m.text,
+                    id: m.id,
+                    level: /^#/.test(m.text || "") ? "info" : "warning",
+                    ts: m.ts || Date.now(),
+                }));
+                if (this.top_tab === "console" && this.sub_tab === "messages") {
+                    this.messages_seen = this.messages_log.length;
+                }
+            },
+            deep: true,
+            immediate: true,
+        },
     },
 
     events: {
@@ -227,6 +251,19 @@ module.exports = new Vue({
     },
 
     computed: {
+        // True when the UI is in kiosk mode — i.e. running on the
+        // controller's own onboard browser (Pi 3B at 1366x768) or
+        // explicitly forced via ?kiosk=1. Source-of-truth is the
+        // `kiosk-mode` class added to <html> by the inline script
+        // in index.pug, which already honors hostname + URL param +
+        // localStorage. The Pi's VideoCore IV is too slow for the
+        // three.js toolpath preview, so we suppress that panel in
+        // kiosk mode and let the gcode listing take the full width.
+        is_kiosk: function() {
+            return typeof document !== "undefined"
+                && document.documentElement.classList.contains("kiosk-mode");
+        },
+
         popupMessages: function() {
             const msgs = [];
 
@@ -252,18 +289,131 @@ module.exports = new Vue({
         enable_rotary: function() {
             if(this.state["2an"] == 1 || this.state["2an"] == 3) return true;
             return false;
-        }
+        },
+
+        // ---------------- header chrome helpers ----------------
+
+        // Underlying machine state from the controller. Mirrors
+        // control-view's `mach_state` so the header has access without
+        // depending on the routed component.
+        mach_state: function() {
+            const cycle = this.state.cycle;
+            const xx = this.state.xx;
+
+            if (xx != "ESTOPPED" && (cycle == "jogging" || cycle == "homing")) {
+                return cycle.toUpperCase();
+            }
+
+            return xx || "";
+        },
+
+        // Short text for the READY pill in the header.
+        state_label: function() {
+            const s = this.mach_state;
+            if (!s) return "--";
+            return s;
+        },
+
+        // Class added to the READY pill (.state-badge) so styling can
+        // reflect ready / running / holding / fault / estop.
+        state_class: function() {
+            const s = this.mach_state;
+            if (s == "ESTOPPED" || s == "FAULT" || s == "SHUTDOWN") return "bad";
+            if (s == "HOLDING" || s == "STOPPING") return "warn";
+            if (s == "RUNNING" || s == "HOMING" || s == "JOGGING") return "busy";
+            if (s == "READY") return "ok";
+            return "unknown";
+        },
+
+        mach_state_full: function() {
+            const s = this.mach_state;
+            if (s == "ESTOPPED") return "E-Stopped \u2014 release to clear";
+            if (s == "HOLDING")  return "Feed hold (" + (this.state.pr || "paused") + ")";
+            if (s == "RUNNING")  return "Running program";
+            if (s == "HOMING")   return "Homing axes";
+            if (s == "JOGGING")  return "Jogging";
+            if (s == "READY")    return "Ready";
+            return s;
+        },
+
+        // Pip color for the unified system pill.
+        sys_class: function() {
+            const wifi_off = !this.config.wifiName || this.config.wifiName == "not connected";
+            const cam_off  = !this.has_camera;
+            const hot      = this.state && 80 <= this.state.rpi_temp;
+            if (hot) return "red";
+            if (wifi_off || cam_off) return "amber";
+            return "green";
+        },
+
+        // Compact summary for the system pill.
+        sys_summary: function() {
+            const issues = [];
+            if (!this.config.wifiName || this.config.wifiName == "not connected") {
+                issues.push("WiFi off");
+            }
+            if (!this.has_camera) issues.push("Camera offline");
+            if (this.state && 80 <= this.state.rpi_temp) issues.push("Pi hot");
+            if (this.is_rotary_active) issues.push("Rotary");
+            if (issues.length === 0) return "All systems";
+            if (issues.length === 1) return issues[0];
+            return issues.length + " notes";
+        },
+
+        // Number of unread Console > Messages entries.
+        messages_count: function() {
+            return Math.max(0, this.messages_log.length - this.messages_seen);
+        },
     },
 
     ready: function() {
         window.onhashchange = () => this.parse_hash();
+
+        // Embedded Svelte subviews (A axis settings, etc.) signal
+        // unsaved changes via this event. The master Save button
+        // highlights when modified is true.
+        window.addEventListener("onefin:dirty", () => {
+            this.modified = true;
+        });
+
+
+
+        // Resolve the initial route before the websocket connects so
+        // the shell shows the right view even on a slow / offline
+        // controller. update() will call parse_hash() again once the
+        // first config is in. Skip routing into the Svelte settings
+        // family before config has loaded — those components read
+        // many config keys (settings.units, settings.probing-prompts,
+        // motion.*, etc.) and would throw on first paint with the
+        // empty placeholder config.
+        const settingsFamily = [
+            "settings", "probing", "gcode",
+            "admin-general", "admin-network",
+            "motor", "tool", "io", "macros",
+            "help", "cheat-sheet",
+            "a-axis",
+        ];
+        const initialHead = (location.hash || "").replace(/^#/, "").split(":")[0];
+        if (settingsFamily.indexOf(initialHead) === -1) {
+            this.parse_hash();
+        }
+        // else: stay on "loading" until update() completes and calls
+        // parse_hash() itself.
+
         this.connect();
 
+        // Close the system popover when clicking anywhere else.
+        document.addEventListener("click", () => {
+            if (this.sys_open) this.sys_open = false;
+        });
+
         SvelteComponents.registerControllerMethods({
             dispatch: (...args) => this.$dispatch(...args)
         });
     },
 
+
+
     methods: {
         block_error_dialog: function() {
             this.errorTimeoutStart = Date.now();
@@ -338,6 +488,12 @@ module.exports = new Vue({
         toggle_rotary: async function(isActive) {
             try {
                 await api.put("rotary", {status: isActive});
+                // The /api/rotary endpoint rewrites motors[1]/[2]
+                // in config.json on the server. Refetch so the UI
+                // reflects the new motor config (otherwise the
+                // motor settings page keeps showing pre-toggle
+                // values until the next page reload).
+                await this.update();
               } catch (error) {
                 console.error(error);
                 alert("Error occured");
@@ -372,11 +528,19 @@ module.exports = new Vue({
         connect: function() {
             this.sock = new Sock(`//${location.host}/sockjs`);
 
+            let _gotFirstMsg = false;
+            let _gotFirstState = false;
+
             this.sock.onmessage = (e) => {
                 if (typeof e.data != "object") {
                     return;
                 }
 
+                if (!_gotFirstMsg) {
+                    _gotFirstMsg = true;
+                    restartTiming.onWsFirstMessage();
+                }
+
                 if (e.data.log && e.data.log.msg !== "Switch not found") {
                     this.$broadcast("log", e.data.log);
 
@@ -386,6 +550,11 @@ module.exports = new Vue({
                     }
                 }
 
+                if (!_gotFirstState) {
+                    _gotFirstState = true;
+                    restartTiming.onFirstState();
+                }
+
                 // Check for session ID change on controller
                 if ("sid" in e.data) {
                     if (typeof this.sid == "undefined") {
@@ -410,6 +579,7 @@ module.exports = new Vue({
 
             this.sock.onopen = () => {
                 this.status = "connected";
+                restartTiming.onWsOpen();
                 this.$emit(this.status);
                 this.$broadcast(this.status);
             };
@@ -421,6 +591,21 @@ module.exports = new Vue({
             };
         },
 
+        // Maps a URL hash to (currentView, top_tab, sub_tab, index).
+        // Hash layouts supported (all kept for backward compat):
+        //   #control                    -> control tab
+        //   #program[:auto]              -> program tab
+        //   #console[:mdi|messages|indicators]
+        //                                -> console tab
+        //   #settings                    -> settings tab home
+        //   #admin-general               -> settings tab, admin-general inside
+        //   #admin-network               -> settings tab, admin-network inside
+        //   #motor:0..3                  -> settings tab, motor 0..3
+        //   #tool                        -> settings tab, tool view
+        //   #io                          -> settings tab, io view
+        //   #macros                      -> settings tab, macros view
+        //   #help                        -> settings tab, help view
+        //   #cheat-sheet                 -> settings tab, cheat sheet view
         parse_hash: function() {
             const hash = location.hash.substr(1);
 
@@ -430,12 +615,58 @@ module.exports = new Vue({
             }
 
             const parts = hash.split(":");
+            const head = parts[0];
 
-            if (parts.length == 2) {
-                this.index = parts[1];
+            this.index = parts.length > 1 ? parts[1] : -1;
+
+            // Legacy / settings-managed views resolve under the
+            // Settings tab while keeping their existing top-level
+            // hash. This preserves all existing deep links.
+            const settingsViews = [
+                "settings", "probing", "gcode",
+                "admin-general", "admin-network",
+                "motor", "tool", "io", "macros",
+                "help", "cheat-sheet",
+                "a-axis",
+            ];
+
+            if (head == "control") {
+                this.top_tab = "control";
+                this.sub_tab = "";
+                this.currentView = "control";
+            } else if (head == "program") {
+                this.top_tab = "program";
+                this.sub_tab = parts[1] || "auto";
+                this.currentView = "program";
+            } else if (head == "console") {
+                this.top_tab = "console";
+                this.sub_tab = parts[1] || "mdi";
+                this.currentView = "console";
+            } else if (settingsViews.indexOf(head) !== -1) {
+                this.top_tab = "settings";
+                this.sub_tab = head;
+                // All settings-family routes mount the same shell;
+                // shell picks inner view from sub_tab. Vary the
+                // currentView token so Vue 1 fully remounts the
+                // shell on every navigation — this avoids stale :class
+                // bindings against the local `sub` data prop.
+                this.currentView = "settings-shell";
+            } else {
+                // Unknown hash: route to settings shell anyway so we
+                // never end up rendering a bare loading screen.
+                this.top_tab = "settings";
+                this.sub_tab = head;
+                this.currentView = "settings-shell";
             }
 
-            this.currentView = parts[0];
+            // Mark Console messages as seen when we enter that tab.
+            if (this.top_tab == "console" && this.sub_tab == "messages") {
+                this.messages_seen = this.messages_log.length;
+            }
+        },
+
+        toggle_sys_popover: function() {
+            this.sys_open = !this.sys_open;
         },
 
         save: async function() {
@@ -455,9 +686,16 @@ module.exports = new Vue({
 
             this.config["selected-tool-settings"][selected_tool] = settings;
             this.display_units = this.config.settings["units"];
-            
+
             try {
                 await api.put("config/save", this.config);
+                // Notify any embedded Svelte subviews that own their
+                // own persistence (A axis -> aux.json, etc.) that
+                // the user just hit the master Save button. They
+                // listen for `onefin:save-all` and PUT their state.
+                try {
+                    window.dispatchEvent(new CustomEvent("onefin:save-all"));
+                } catch (_e) {}
                 this.modified = false;
             } catch (error) {
                 console.error("Save failed:", error);

src/js/axis-vars.js

@@ -32,6 +32,10 @@ module.exports = {
             return this._compute_axis("c");
         },
 
+        w: function() {
+            return this._compute_aux_axis();
+        },
+
         axes: function() {
             return this._compute_axes();
         }
@@ -52,7 +56,12 @@ module.exports = {
             const abs = this.state[`${axis}p`] || 0;
             const off = this.state[`offset_${axis}`];
             const motor_id = this._get_motor_id(axis);
-            const motor = motor_id == -1 ? {} : this.config.motors[motor_id];
+            // motor_id may be 4 for the synthetic external-axis motor;
+            // there is no entry for it in config.motors so guard with
+            // an empty object to avoid undefined property access.
+            const motor = (motor_id == -1
+                ? {}
+                : (this.config.motors[motor_id] || {}));
             const enabled = this._check_is_enabled(axis);
             const homingMode = motor["homing-mode"];
             const homed = this.state[`${motor_id}homed`];
@@ -185,24 +194,114 @@ module.exports = {
         _get_motor_id: function(axis) {
             for (let i = 0; i < this.config.motors.length; i++) {
                 const motor = this.config.motors[i];
-                if (motor.axis.toLowerCase() == axis) {
+                // motor.axis can be undefined on initial load before
+                // config has streamed in. Guard so the computed does
+                // not throw and bubble a Vue warning into the console.
+                if (motor && typeof motor.axis === "string" &&
+                    motor.axis.toLowerCase() == axis) {
                     return i;
                 }
             }
 
+            // Synthetic external motor (index 4) used by ExternalAxis
+            // to expose the auxcnc ESP stepper as a virtual axis.
+            // Its `Nan` lives in state, not config.
+            const axes = { x: 0, y: 1, z: 2, a: 3, b: 4, c: 5 };
+            const wanted = axes[axis];
+            const extAn = this.state && this.state["4an"];
+            if (typeof wanted === "number" && typeof extAn === "number"
+                && extAn === wanted) {
+                return 4;
+            }
+
             return -1;
         },
 
         _check_is_enabled: function(axis){
+            // Prefer config.motors[i].axis (always present once the
+            // config has loaded). Fall back to the per-motor state
+            // `Nan` field, which is what the legacy UI used. This
+            // avoids hiding axis rows during the brief window after
+            // config has loaded but before the controller has pushed
+            // its first state delta.
             const axes = { x: 0, y: 1, z: 2, a: 3 };
-            for(let i = 0; i < this.config.motors.length; i++){
-                if(this.state[`${i}an`] == axes[axis]){
+            const wanted = axes[axis];
+            for (let i = 0; i < this.config.motors.length; i++) {
+                const motor = this.config.motors[i] || {};
+                if (typeof motor.axis === "string" &&
+                    motor.axis.toLowerCase() == axis) {
+                    return motor.enabled !== false;
+                }
+                // Only use the state Nan fallback for axes we know
+                // about (x/y/z/a). Otherwise undefined == undefined
+                // would mistakenly match every axis (b, c, ...).
+                if (typeof wanted === "number") {
+                    const an = this.state[`${i}an`];
+                    if (typeof an === "number" && an === wanted) {
+                        return true;
+                    }
+                }
+            }
+            // Synthetic external motor (index 4) - the auxcnc ESP
+            // stepper exposed as A via ExternalAxis.
+            if (typeof wanted === "number") {
+                const extAn = this.state["4an"];
+                const extMe = this.state["4me"];
+                if (typeof extAn === "number" && extAn === wanted
+                    && extMe) {
                     return true;
                 }
             }
             return false;
         },
 
+        _compute_aux_axis: function() {
+            // Auxiliary axis driven by the auxcnc ESP32 (typically
+            // exposed to gplan as A). Position, homed flag and
+            // presence come from the bbctrl AuxAxis driver via
+            // state.aux_*. No motor mapping, no soft-limit warnings
+            // on toolpath bounds (auxcnc enforces its own).
+            const enabled = !!this.state.aux_enabled;
+            const present = !!this.state.aux_present;
+            const homed   = !!this.state.aux_homed;
+            const pos     = this.state.aux_pos || 0;
+
+            let klass = `${homed ? "homed" : "unhomed"} axis-w`;
+            let state = present ? "UNHOMED" : "OFFLINE";
+            let icon  = present ? "question-circle" : "plug";
+            let title = present
+                ? "Click the home button to home the auxiliary axis."
+                : "Aux controller not connected on /dev/ttyUSB0.";
+            if (homed) {
+                state = "HOMED";
+                icon  = "check-circle";
+                title = "Auxiliary axis successfully homed.";
+            } else if (!present) {
+                klass += " error";
+            }
+
+            return {
+                pos: pos,
+                abs: pos,
+                off: 0,
+                min: 0, max: 0, dim: 0,
+                pathMin: 0, pathMax: 0, pathDim: 0,
+                motor: -1,
+                enabled: enabled,
+                homingMode: "limit-switch",
+                homed: homed,
+                klass: klass,
+                state: state,
+                icon: icon,
+                title: title,
+                ticon: "check-circle",
+                tstate: "OK",
+                toolmsg: "Auxiliary axis is not constrained by tool path bounds.",
+                tklass: `${homed ? "homed" : "unhomed"} axis-w`,
+                isAux: true,
+            };
+        },
+
         _compute_axes: function() {
             let homed = false;
 

src/js/console-view.js

@@ -0,0 +1,125 @@
+"use strict";
+
+const api = require("./api");
+
+// Console tab — MDI command input, message log and live indicators.
+// Sub-tab state syncs with the URL hash (#console:mdi |
+// #console:messages | #console:indicators) so deep links work.
+
+module.exports = {
+  template: "#console-view-template",
+  props: ["config", "template", "state"],
+
+  data: function () {
+    return {
+      mdi: "",
+      history: [],
+      sub: "mdi",
+      // Local mirror of $root.messages_count so Vue 1 reactivity works.
+      unread_messages_local: 0,
+    };
+  },
+
+  watch: {
+    sub: function () {
+      // Switching to messages marks them as seen so the header badge
+      // clears.
+      if (this.sub === "messages") {
+        this.$root.messages_seen = this.$root.messages_log.length;
+        this.unread_messages_local = 0;
+      }
+    },
+  },
+
+  computed: {
+    unread_messages: function () {
+      return this.unread_messages_local;
+    },
+
+    mach_state: function () {
+      const cycle = this.state.cycle;
+      const xx = this.state.xx;
+      if (xx != "ESTOPPED" && (cycle == "jogging" || cycle == "homing")) {
+        return cycle.toUpperCase();
+      }
+      return xx || "";
+    },
+
+    is_idle: function () { return this.state.cycle == "idle"; },
+
+    can_mdi: function () {
+      return this.is_idle || this.state.cycle == "mdi";
+    },
+
+    mach_units: function () {
+      return this.$root.display_units;
+    },
+  },
+
+  ready: function () {
+    this._onHash = () => this.refresh_from_hash();
+    window.addEventListener("hashchange", this._onHash);
+    this.refresh_from_hash();
+    this._poll = setInterval(() => {
+      // Cheap re-poll for unread message count; Vue 1 cannot observe
+      // `$root.messages_count` directly so we mirror it here.
+      const c = this.$root && this.$root.messages_count;
+      if (typeof c === "number" && c !== this.unread_messages_local) {
+        this.unread_messages_local = c;
+      }
+    }, 500);
+  },
+
+  beforeDestroy: function () {
+    if (this._onHash) window.removeEventListener("hashchange", this._onHash);
+    if (this._poll) clearInterval(this._poll);
+  },
+
+  methods: {
+    refresh_from_hash: function () {
+      const hash = location.hash.substr(1);
+      const parts = hash.split(":");
+      const sub = parts[0] === "console" ? (parts[1] || "mdi") : "mdi";
+      this.sub = sub;
+      if (sub === "messages" && this.$root) {
+        this.$root.messages_seen = this.$root.messages_log.length;
+        this.unread_messages_local = 0;
+      }
+    },
+
+    select_sub: function (name) {
+      this.sub = name;
+      // Update URL hash for deep links / back-button.
+      const h = "#console" + (name && name !== "mdi" ? ":" + name : "");
+      if (location.hash !== h) {
+        history.replaceState(null, "", h);
+      }
+      if (name === "messages") {
+        this.$root.messages_seen = this.$root.messages_log.length;
+        this.unread_messages_local = 0;
+      }
+    },
+
+    prepend: function (token) {
+      this.mdi = token + this.mdi.trimStart();
+    },
+
+    append: function (token) {
+      const tail = this.mdi.endsWith(" ") || !this.mdi ? "" : " ";
+      this.mdi = this.mdi + tail + token;
+    },
+
+    submit_mdi: function () {
+      if (!this.mdi) return;
+      this.$dispatch("send", this.mdi);
+      if (!this.history.length || this.history[0] != this.mdi) {
+        this.history.unshift(this.mdi);
+      }
+      this.mdi = "";
+    },
+
+    load_history: function (index) {
+      this.mdi = this.history[index];
+    },
+  },
+};

src/js/control-view.js

@@ -1,7 +1,6 @@
 "use strict";
 
 const api = require("./api");
-const utils = require("./utils");
 const cookie = require("./cookie")("bbctrl-");
 
 module.exports = {
@@ -12,15 +11,7 @@ module.exports = {
     return {
       current_time: "",
       mach_units: this.$root.state.metric ? "METRIC" : "IMPERIAL",
-      mdi: "",
-      last_file: undefined,
-      last_file_time: undefined,
-      toolpath: {},
-      toolpath_progress: 0,
       axes: "xyzabc",
-      history: [],
-      speed_override: 1,
-      feed_override: 1,
       jog_incr_amounts: {
         METRIC: {
           fine: 0.1,
@@ -38,34 +29,14 @@ module.exports = {
       jog_incr: localStorage.getItem("jog_incr") || "small",
       jog_step: cookie.get_bool("jog-step"),
       jog_adjust: parseInt(cookie.get("jog-adjust", 2)),
-      deleteGCode: false,
-      tab: "auto",
       ask_home: true,
-      folder_name: "",
-      edited: false,
-      uploading_files: false,
-      confirmDelete: false,
-      create_folder: false,
-      showGcodeMessage: false,
-      showNoGcodeMessage: false,
-      macrosLoading: false,
-      show_gcodes: false,
-      GCodeNotFound: false,
       show_probe_dialog: false,
-      filesUploaded: 0,
-      totalFiles: 0,
-      files_sortby: "By Upload Date",
-      selected_items_to_delete: [],
-      search_query: "",
-      filtered_files: [],
-      selected_folder_index: null,
+      overrides_open: false,
     };
   },
 
   components: {
     "axis-control": require("./axis-control"),
-    "path-viewer": require("./path-viewer"),
-    "gcode-viewer": require("./gcode-viewer"),
   },
 
   watch: {
@@ -80,16 +51,6 @@ module.exports = {
       immediate: true,
     },
 
-    "state.line": function () {
-      if (this.mach_state != "HOMING") {
-        this.$broadcast("gcode-line", this.state.line);
-      }
-    },
-
-    "state.selected_time": function () {
-      this.load();
-    },
-
     jog_step: function () {
       cookie.set_bool("jog-step", this.jog_step);
     },
@@ -127,43 +88,16 @@ module.exports = {
       return state || "";
     },
 
-    pause_reason: function () {
-      return this.state.pr;
-    },
-
-    is_running: function () {
-      return this.mach_state == "RUNNING" || this.mach_state == "HOMING";
-    },
-
-    is_stopping: function () {
-      return this.mach_state == "STOPPING";
-    },
-
-    is_holding: function () {
-      return this.mach_state == "HOLDING";
-    },
-
-    is_ready: function () {
-      return this.mach_state == "READY";
+    can_set_axis: function () {
+      return this.state.cycle == "idle";
     },
 
     is_idle: function () {
       return this.state.cycle == "idle";
     },
 
-    is_paused: function () {
-      return this.is_holding && (this.pause_reason == "User pause" || this.pause_reason == "Program pause");
-    },
-
-    can_mdi: function () {
-      return this.is_idle || this.state.cycle == "mdi";
-    },
-
-    can_set_axis: function () {
-      return this.is_idle;
-
-      // TODO allow setting axis position during pause
-      // return this.is_idle || this.is_paused;
+    is_ready: function () {
+      return this.mach_state == "READY";
     },
 
     message: function () {
@@ -191,57 +125,21 @@ module.exports = {
     },
 
     plan_time_remaining: function () {
-      if (!(this.is_stopping || this.is_running || this.is_holding)) {
-        return 0;
-      }
-
-      return this.toolpath.time - this.plan_time;
+      const stopping = this.mach_state == "STOPPING";
+      const running  = this.mach_state == "RUNNING" || this.mach_state == "HOMING";
+      const holding  = this.mach_state == "HOLDING";
+      if (!(stopping || running || holding)) return 0;
+      const tp = this.$root && this.$root.toolpath ? this.$root.toolpath.time : 0;
+      return (tp || 0) - this.plan_time;
     },
 
-    eta: function () {
-      if (this.mach_state != "RUNNING") {
-        return "";
-      }
-
-      const remaining = this.plan_time_remaining;
-      const d = new Date();
-      d.setSeconds(d.getSeconds() + remaining);
-      return d.toLocaleString();
-    },
-
-    progress: function () {
-      if (!this.toolpath.time || this.is_ready) {
-        return 0;
-      }
-
-      const p = this.plan_time / this.toolpath.time;
-      return Math.min(1, p);
-    },
-    gcode_files: function () {
-      if (!this.state.folder) {
-        return [];
-      }
-      const folder = this.state.gcode_list.find(item => item.name == this.state.folder);
-      if (!folder) {
-        return [];
-      }
-      const files = folder.files.filter(item => this.state.files.includes(item.file_name)).map(item => item.file_name);
-      if (this.files_sortby == "A-Z") {
-        return files.sort();
-      } else if (this.files_sortby == "Z-A") {
-        return files.sort().reverse();
-      } else {
-        return files;
-      }
-    },
-    gcode_filtered_files: function () {
-      return this.filtered_files.filter(file => file.toLowerCase().includes(this.search_query.toLowerCase()));
-    },
-    gcode_folders: function () {
-      return this.state.gcode_list
-        .map(item => item.name)
-        .filter(element => element !== "default")
-        .sort();
+    state_kpi_class: function () {
+      const s = this.mach_state;
+      if (s == "ESTOPPED" || s == "FAULT" || s == "SHUTDOWN") return "bad";
+      if (s == "HOLDING" || s == "STOPPING") return "warn";
+      if (s == "RUNNING" || s == "HOMING" || s == "JOGGING") return "busy";
+      if (s == "READY") return "ok";
+      return "";
     },
   },
 
@@ -264,14 +162,9 @@ module.exports = {
                 M72
             `);
     },
-    folder_name_edited: function () {
-      this.edited = true;
-    },
   },
 
   ready: function () {
-    this.load();
-
     setInterval(() => {
       this.current_time = new Date().toLocaleTimeString();
     }, 1000);
@@ -287,28 +180,39 @@ module.exports = {
   },
 
   methods: {
-    save_config: async function (config) {
-      try {
-        await api.put("config/save", config);
-        this.$dispatch("update");
-      } catch (error) {
-        console.error("Restore Failed: ", error);
-        alert("Restore failed");
-      }
-    },
-
-    populateFiles(index) {
-      this.selected_folder_index = index;
-      this.filtered_files = this.state.gcode_list[index].files.map(item => item.file_name);
-    },
-
     getJogIncrStyle(value) {
       const weight = `font-weight:${this.jog_incr === value ? "bold" : "normal"}`;
       const color = this.jog_incr === value ? "color:#0078e7" : "";
-
       return [weight, color].join(";");
     },
 
+    // Should the macro row render a colored left stripe for this
+    // macro? Only when the user has explicitly picked a color. The
+    // controller seeds new macros with default placeholders like
+    // "#ffffff" or "#dedede"; treat anything that close to white as
+    // "no color".
+    has_macro_color(macros) {
+      if (!macros || typeof macros.color !== "string") return false;
+      const c = macros.color.trim().toLowerCase();
+      if (!c) return false;
+      const defaults = [
+        "#fff", "#ffffff", "#fefefe", "#fdfdfd", "#fcfcfc",
+        "#dedede", "#dddddd", "#cccccc",
+      ];
+      if (defaults.indexOf(c) !== -1) return false;
+      // Fallback: if the color is very close to white (sum of RGB
+      // > 690), suppress the stripe.
+      const m = c.match(/^#([0-9a-f]{6})$/);
+      if (m) {
+        const v = parseInt(m[1], 16);
+        const r = (v >> 16) & 0xff;
+        const g = (v >> 8) & 0xff;
+        const b = v & 0xff;
+        if (r + g + b > 690) return false;
+      }
+      return true;
+    },
+
     jog_fn: function (x_jog, y_jog, z_jog, a_jog) {
       const amount = this.jog_incr_amounts[this.display_units][this.jog_incr];
 
@@ -324,426 +228,6 @@ module.exports = {
             `);
     },
 
-    send: function (msg) {
-      this.$dispatch("send", msg);
-    },
-
-    toggle_sorting: function () {
-      if (this.files_sortby === "By Upload Date") {
-        this.files_sortby = "A-Z";
-      } else if (this.files_sortby === "A-Z") {
-        this.files_sortby = "Z-A";
-      } else if (this.files_sortby === "Z-A") {
-        this.files_sortby = "By Upload Date";
-      }
-    },
-
-    load: function () {
-      const file_time = this.state.selected_time;
-      const file = this.state.selected;
-      if (this.last_file == file && this.last_file_time == file_time) {
-        return;
-      }
-
-      if (this.state.selected && !this.state.files.includes(this.state.selected)) {
-        this.GCodeNotFound = true;
-        return;
-      }
-
-      this.last_file = file;
-      this.last_file_time = file_time;
-
-      this.$broadcast("gcode-load", file);
-      this.$broadcast("gcode-line", this.state.line);
-      this.toolpath_progress = 0;
-      this.load_toolpath(file, file_time);
-    },
-
-    load_toolpath: async function (file, file_time) {
-      this.toolpath = {};
-
-      if (!file || this.last_file_time != file_time) {
-        return;
-      }
-
-      this.showGcodeMessage = true;
-
-      while (this.showGcodeMessage) {
-        try {
-          const toolpath = await api.get(`path/${file}`);
-          this.toolpath_progress = toolpath.progress;
-
-          if (toolpath.progress === 1 || typeof toolpath.progress == "undefined") {
-            this.showGcodeMessage = false;
-
-            if (toolpath.bounds) {
-              toolpath.filename = file;
-              this.toolpath_progress = 1;
-              this.toolpath = toolpath;
-
-              const state = this.$root.state;
-              for (const axis of "xyzabc") {
-                Vue.set(state, `path_min_${axis}`, toolpath.bounds.min[axis]);
-                Vue.set(state, `path_max_${axis}`, toolpath.bounds.max[axis]);
-              }
-            }
-          }
-        } catch (error) {
-          console.error(error);
-        }
-      }
-    },
-
-    submit_mdi: function () {
-      this.send(this.mdi);
-
-      if (!this.history.length || this.history[0] != this.mdi) {
-        this.history.unshift(this.mdi);
-      }
-
-      this.mdi = "";
-    },
-
-    mdi_start_pause: function () {
-      if (this.state.xx == "RUNNING") {
-        this.pause();
-      } else if (this.state.xx == "STOPPING" || this.state.xx == "HOLDING") {
-        this.unpause();
-      } else {
-        this.submit_mdi();
-      }
-    },
-
-    load_history: function (index) {
-      this.mdi = this.history[index];
-    },
-
-    open_file: function () {
-      utils.clickFileInput("gcode-file-input");
-    },
-
-    open_folder: function () {
-      utils.clickFileInput("gcode-folder-input");
-    },
-
-    edited_folder_name: function (event) {
-      if (event.target.value.trim() != "") {
-        this.$dispatch("folder_name_edited");
-      }
-    },
-
-    update_config: function () {
-      this.config.gcode_list = [...this.state.gcode_list];
-      this.config.non_macros_list = [...this.state.non_macros_list];
-      this.config.macros_list = [...this.state.macros_list];
-      this.config.macros = [...this.state.macros];
-    },
-
-    reset_gcode: function () {
-      this.state.selected = "";
-      this.last_file = "";
-      this.$broadcast("gcode-load", "");
-    },
-
-    upload_gcode: async function (filename, file) {
-      return new Promise((resolve, reject) => {
-        const xhr = new XMLHttpRequest();
-
-        this.filesUploaded++;
-        if (this.filesUploaded == this.totalFiles) {
-          this.uploading_files = false;
-        }
-
-        xhr.onload = () => {
-          if (xhr.status >= 200 && xhr.status < 300) {
-            resolve("file uploaded");
-          } else {
-            console.error("File upload failed:", xhr.statusText);
-            reject("upload failed");
-          }
-        };
-
-        xhr.onerror = () => {
-          alert("Upload failed.");
-          reject("upload failed");
-        };
-
-        xhr.open("PUT", `/api/file/${encodeURIComponent(filename)}`, true);
-        xhr.send(file);
-      });
-    },
-
-    readFile: function (file) {
-      return new Promise((resolve, reject) => {
-        const reader = new FileReader();
-
-        reader.onload = () => {
-          resolve(reader.result);
-        };
-
-        reader.onerror = error => {
-          reject(error);
-        };
-
-        reader.readAsText(file, "utf-8");
-      });
-    },
-
-    validateFiles: async function (files) {
-      const validFiles = [];
-      for (const file of files) {
-        const extension = file.name.split(".").pop().toLowerCase();
-        const validExtensions = ["nc", "ngc", "gcode", "gc"];
-
-        if (validExtensions.includes(extension)) {
-          validFiles.push(file);
-        } else {
-          alert(`Unsupported file : ${file.name}`);
-          this.filesUploaded++;
-          if (this.filesUploaded == this.totalFiles) {
-            this.uploadFiles = false;
-          }
-        }
-      }
-
-      return validFiles;
-    },
-
-    uploadValidFiles: async function (files, folderName) {
-      const updatedConfig = { ...this.config };
-
-      for (const file of files) {
-        try {
-          const gcode = await this.readFile(file);
-          await this.upload_gcode(file.name, gcode);
-
-          const isAlreadyPresent = updatedConfig.non_macros_list.some(element => element.file_name === file.name);
-
-          if (!isAlreadyPresent) {
-            updatedConfig.non_macros_list.push({ file_name: file.name });
-          }
-
-          if (folderName) {
-            const folder = updatedConfig.gcode_list.find(item => item.type == "folder" && item.name == folderName);
-            if (folder) {
-              if (!folder.files.map(item => item.file_name).includes(file.name)) {
-                folder.files.push({ file_name: file.name });
-              }
-            } else {
-              updatedConfig.gcode_list.push({
-                name: folderName,
-                type: "folder",
-                files: [
-                  {
-                    file_name: file.name,
-                  },
-                ],
-              });
-            }
-          } else {
-            var folder_to_add = updatedConfig.gcode_list.find(
-              item => item.type == "folder" && item.name == this.state.folder,
-            );
-            if (!folder_to_add) {
-              folder_to_add = updatedConfig.gcode_list.unshift({
-                name: this.state.folder,
-                type: "folder",
-                files: [
-                  {
-                    file_name: file.name,
-                  },
-                ],
-              });
-              folder_to_add = updatedConfig.gcode_list[0];
-            }
-            if (!folder_to_add.files.find(item => item.file_name == file.name)) {
-              folder_to_add.files.push({ file_name: file.name });
-            }
-          }
-        } catch (error) {
-          console.warn(`error uploading file : `, error);
-        }
-      }
-      return updatedConfig;
-    },
-
-    upload_files: async function (files, folderName) {
-      this.update_config();
-
-      const validFiles = await this.validateFiles(files);
-      const updatedConfig = await this.uploadValidFiles(validFiles, folderName);
-
-      await this.save_config(updatedConfig);
-    },
-
-    upload_file: async function (e) {
-      this.uploading_files = true;
-      this.filesUploaded = 0;
-
-      const files = e.target.files || e.dataTransfer.files;
-      if (!files.length) {
-        return;
-      }
-
-      this.totalFiles = files.length;
-
-      await this.upload_files(files);
-    },
-
-    create_new_folder: async function () {
-      const folder_name = this.folder_name.trim();
-      if (folder_name != "") {
-        if (this.state.gcode_list.find(item => item.type == "folder" && item.name == folder_name)) {
-          alert("Folder with the same name already exists!");
-          return;
-        } else {
-          this.update_config();
-          this.config.gcode_list.push({
-            name: folder_name,
-            type: "folder",
-            files: [],
-          });
-        }
-        this.state.folder = folder_name;
-        this.edited = false;
-        this.create_folder = false;
-        this.folder_name = "";
-        this.save_config(this.config);
-      }
-    },
-
-    cancel_new_folder: function () {
-      this.create_folder = false;
-      this.folder_name = "";
-    },
-
-    upload_folder: async function (e) {
-      this.uploading_files = true;
-      this.filesUploaded = 0;
-
-      const files = e.target.files || e.dataTransfer.files;
-      if (!files.length) {
-        return;
-      }
-      this.totalFiles = files.length;
-      const folderName = files[0].webkitRelativePath.split("/")[0];
-
-      this.upload_files(files, folderName);
-    },
-
-    delete_current: async function () {
-      if (!this.state.selected) {
-        this.deleteGCode = false;
-        return;
-      }
-
-      this.update_config();
-
-      this.config.non_macros_list = this.config.non_macros_list.filter(
-        item => !this.selected_items_to_delete.includes(item.file_name),
-      );
-      const folder_to_update = this.config.gcode_list.find(
-        item => item.name == this.config.gcode_list[this.selected_folder_index].name && item.type == "folder",
-      );
-      folder_to_update.files = folder_to_update.files.filter(
-        item => !this.selected_items_to_delete.includes(item.file_name),
-      );
-
-      const exception_list = this.state.macros_list.map(item => item.file_name);
-      let files_to_delete = this.selected_items_to_delete.filter(item => !exception_list.includes(item));
-
-      await api.delete(`file/DINCAIQABiDARixAxiABDIHCAMQABiABDIHCAQQABiABDIH${files_to_delete.toString()}`);
-
-      this.save_config(this.config);
-      this.filtered_files = [];
-      this.search_query = "";
-      this.selected_folder_index = null;
-      this.selected_items_to_delete = [];
-      this.deleteGCode = false;
-    },
-
-    cancel_delete: function () {
-      this.filtered_files = [];
-      this.search_query = "";
-      this.selected_folder_index = null;
-      this.selected_items_to_delete = [];
-      this.deleteGCode = false;
-    },
-
-    delete_all: function () {
-      api.delete("file");
-      this.deleteGCode = false;
-    },
-
-    delete_all_except_macros: async function () {
-      this.update_config();
-      const macrosList = this.state.macros_list.map(item => item.file_name).toString();
-      api.delete(`file/EgZjaHJvbWUqCggBEAAYsQMYgAQyBggAEEUYOTIKCAE${macrosList}`);
-      this.config.non_macros_list = [];
-      this.config.gcode_list = [
-        {
-          name: "default",
-          type: "folder",
-          files: [],
-        },
-      ];
-
-      this.save_config(this.config);
-      this.state.folder = "default";
-      this.state.selected = "";
-      this.selected_items_to_delete = [];
-      this.deleteGCode = false;
-    },
-
-    delete_folder: async function () {
-      this.update_config();
-      if (this.state.folder && this.state.folder != "default") {
-        const files_to_move = this.config.gcode_list.find(
-          item => item.type == "folder" && item.name == this.state.folder,
-        );
-        if (files_to_move) {
-          const default_folder = this.config.gcode_list.find(item => item.name == "default");
-          default_folder.files = [...default_folder.files, ...files_to_move.files].sort();
-          this.config.gcode_list = this.config.gcode_list.filter(item => item.name != this.state.folder);
-          this.save_config(this.config);
-        }
-      }
-      this.state.folder = "default";
-      this.confirmDelete = false;
-    },
-    delete_folder_and_files: async function () {
-      if (!this.state.folder) {
-        this.confirmDelete = false;
-        return;
-      }
-
-      this.update_config();
-
-      const selected_folder = this.config.gcode_list.find(
-        item => item.type == "folder" && item.name == this.state.folder,
-      );
-      if (!selected_folder) {
-        return;
-      }
-      const macrosList = this.state.macros_list.map(item => item.file_name);
-      var files_to_delete = selected_folder.files
-        .map(item => item.file_name)
-        .filter(item => !macrosList.includes(item));
-      if (selected_folder.name != "default") {
-        this.config.gcode_list = this.config.gcode_list.filter(item => item.name != this.state.folder);
-      } else {
-        selected_folder.files = [];
-      }
-
-      await api.delete(`file/DINCAIQABiDARixAxiABDIHCAMQABiABDIHCAQQABiABDIH${files_to_delete.toString()}`);
-      this.config.non_macros_list = this.config.non_macros_list.filter(
-        item => !files_to_delete.includes(item.file_name),
-      );
-      this.save_config(this.config);
-      this.state.folder = "default";
-      this.confirmDelete = false;
-    },
-
     home: function (axis) {
       this.ask_home = false;
 
@@ -765,6 +249,85 @@ module.exports = {
       api.put(`home/${axis}/clear`);
     },
 
+    aux_home: function () {
+      api.put("aux/home").catch(function (err) {
+        console.error("Aux home failed:", err);
+      });
+    },
+
+    // Home every enabled axis (legacy Onefinity "Home All"). Sequence:
+    //   1. Z, X, Y (and A/B/C if enabled)  via /api/home on the AVR
+    //   2. Auxiliary axis                  via /api/aux/home on the ESP
+    //      ONLY when the auxcnc axis is not integrated as a virtual
+    //      machine axis. With the gplan A-axis integration (synthetic
+    //      motor 4 enabled), Mach.home() already homes the external
+    //      axis as part of the xyzabc pass - calling aux/home
+    //      afterwards would home it a second time.
+    // /api/home returns as soon as the request is queued, not when
+    // homing completes, so we have to watch state.cycle:
+    //   - first wait for it to *leave* 'idle' (cycle began),
+    //   - then wait for it to come *back* to 'idle' (cycle ended).
+    // Only then do we fire the auxiliary home, so the gantry and the
+    // auxcnc ESP never move at the same time.
+    home_all: async function () {
+      this.ask_home = false;
+      try {
+        await api.put("home");
+      } catch (e) {
+        console.error("Home all (XYZ) failed:", e);
+        return;
+      }
+      if (!this.w || !this.w.enabled) return;
+
+      // When the synthetic external motor (index 4) is enabled,
+      // the auxcnc axis is mapped onto a real machine axis letter
+      // (e.g. A) and was already homed by /api/home above.
+      if (this.state && this.state["4me"]) return;
+
+      const wait = (ms) => new Promise(r => setTimeout(r, ms));
+      const cycleNow = () => (this.state && this.state.cycle) || "idle";
+
+      // Phase 1: wait up to 5s for the homing cycle to actually start.
+      // If the request was rejected upstream (e.g. estopped) cycle
+      // never leaves idle and we bail rather than home A in isolation.
+      const startedAt = Date.now();
+      while (Date.now() - startedAt < 5000) {
+        if (cycleNow() != "idle") break;
+        await wait(100);
+      }
+      if (cycleNow() == "idle") {
+        console.warn("home_all: main homing cycle never started; skipping aux");
+        return;
+      }
+
+      // Phase 2: wait up to 2 minutes for the gantry to finish.
+      const settledAt = Date.now();
+      while (Date.now() - settledAt < 120000) {
+        if (cycleNow() == "idle") break;
+        await wait(200);
+      }
+      if (cycleNow() != "idle") {
+        console.warn("home_all: gantry homing did not complete in time");
+        return;
+      }
+
+      api.put("aux/home").catch(function (err) {
+        console.error("Aux home failed:", err);
+      });
+    },
+
+    aux_jog: function (delta_mm) {
+      api.put("aux/jog", { mm: delta_mm }).catch(function (err) {
+        console.error("Aux jog failed:", err);
+      });
+    },
+
+    aux_jog_incr: function (sign) {
+      const amount = this.jog_incr_amounts[this.display_units][this.jog_incr];
+      const delta_mm = sign * (this.metric ? amount : amount * 25.4);
+      this.aux_jog(delta_mm);
+    },
+
     show_set_position: function (axis) {
       SvelteComponents.showDialog("SetAxisPosition", { axis });
     },
@@ -790,93 +353,20 @@ module.exports = {
     },
 
     zero: function (axis) {
-      if (typeof axis == "undefined") {
-        this.zero_all();
-      } else {
-        this.set_position(axis, 0);
-      }
-    },
-
-    start_pause: function () {
-      this.macrosLoading = false;
-      if (this.state.xx == "RUNNING") {
-        this.pause();
-      } else if (this.state.xx == "STOPPING" || this.state.xx == "HOLDING") {
-        this.unpause();
-      } else {
-        this.start();
-      }
-    },
-
-    start: function () {
-      api.put("start");
-    },
-
-    pause: function () {
-      api.put("pause");
-    },
-
-    unpause: function () {
-      api.put("unpause");
-    },
-
-    optional_pause: function () {
-      api.put("pause/optional");
-    },
-
-    stop: function () {
-      api.put("stop");
-    },
-
-    step: function () {
-      api.put("step");
-    },
-
-    override_feed: function () {
-      api.put(`override/feed/${this.feed_override}`);
-    },
-
-    override_speed: function () {
-      api.put(`override/speed/${this.speed_override}`);
-    },
-
-    current: function (axis, value) {
-      const x = value / 32.0;
-      if (this.state[`${axis}pl`] == x) {
-        return;
-      }
-
-      const data = {};
-      data[`${axis}pl`] = x;
-      this.send(JSON.stringify(data));
+      if (typeof axis == "undefined") this.zero_all();
+      else this.set_position(axis, 0);
     },
 
     showProbeDialog: function (probeType) {
-      if(this.show_probe_dialog){
+      if (this.show_probe_dialog) {
         this.show_probe_dialog = false;
       }
-      SvelteComponents.showDialog("Probe", { probeType, isRotaryActive: this.state["2an"] == 3 });
-    },
-    run_macro: function (id) {
-      if (this.state.macros[id].file_name == "default") {
-        this.showNoGcodeMessage = true;
-      } else {
-        if (this.state.macros[id].file_name != this.state.selected) {
-          this.state.selected = this.state.macros[id].file_name;
-        }
-        try {
-          this.load();
-          if (this.state.macros[id].alert == true) {
-            this.macrosLoading = true;
-          } else {
-            setImmediate(() => this.start_pause());
-          }
-        } catch (error) {
-          console.warn("Error running program: ", error);
-        }
-      }
+      SvelteComponents.showDialog("Probe", {
+        probeType,
+        isRotaryActive: this.state["2an"] == 3,
+      });
     },
   },
 
-  mixins: [require("./axis-vars")],
+  mixins: [require("./program-mixin"), require("./axis-vars")],
 };

src/js/io-indicator.js

@@ -49,14 +49,17 @@ module.exports = {
     methods: {
         get_io_state_class: function(active, state) {
             if (typeof active == "undefined" || typeof state == "undefined") {
-                return "fa-exclamation-triangle warn";
+                return "fa-triangle-exclamation warn";
             }
 
+            // Tristated: render as the regular (outline) circle to
+            // distinguish from active/inactive solid circles. Adding
+            // `far` switches to the FA6 regular family.
             if (state == 2) {
-                return "fa-circle-o";
+                return "far fa-circle";
             }
 
-            const icon = state ? "fa-plus-circle" : "fa-minus-circle";
+            const icon = state ? "fa-circle-plus" : "fa-circle-minus";
             return `${icon} ${active ? "active" : "inactive"}`;
         },
 

src/js/main.js

@@ -44,6 +44,16 @@ window.onload = function() {
         cookie_set("client-id", uuid(), 10000);
     }
 
+    // Vue 1's async queue can drop dependent watcher updates when
+    // data props are mutated outside the normal event flow (e.g. from
+    // a `hashchange` listener that fires before Vue's tick scheduler
+    // has caught up). Disable async batching so every reactive write
+    // synchronously re-evaluates dependents — this matches Vue 1's
+    // older default and is what the legacy UI implicitly relied on.
+    if (Vue.config) {
+        Vue.config.async = false;
+    }
+
     // Register global components
     Vue.component("templated-input", require("./templated-input"));
     Vue.component("message", require("./message"));

src/js/motor-view.js

@@ -87,100 +87,16 @@ module.exports = {
             return this.stallRPM * this.stepsPerRev * ustep / 60;
         },
 
-        current_axis: function() {
-            return this.state[this.index + 'an'];
-        },
-
-        current_max_velocity: function() {
-            return this.state[this.index + 'vm'];
-        },
-
-        current_max_soft_limit: function() {
-            return this.state[this.index + 'tm'];
-        },
-
-        current_min_soft_limit: function() {
-            return this.state[this.index + 'tn'];
-        },
-        current_max_accel: function() {
-            return this.state[this.index + 'am'];
-        },
-        current_max_jerk: function() {
-            return this.state[this.index + 'jm'];
-        },
-        current_step_angle: function() {
-            return this.state[this.index + 'sa'];
-        },
-        current_travel_per_rev: function() {
-            return this.state[this.index + 'tr'];
-        },
-        current_microsteps: function() {
-            return this.state[this.index + 'mi'];
-        }
-    },
-
-    attached: function() {
-        // Sync all state values with motor config when component is ready
-        // This ensures UI shows correct values when component is first loaded
-        console.log("Syncing state to motor config for motor index ",this.index);
-        this.syncStateToConfig();
-    },
-
-    watch: {
-        current_axis(new_value) {
-            const motor_axes = ["X", "Y", "Z", "A", "B", "C"] 
-            if(motor_axes[new_value] != this.motor['axis']){
-                this.motor['axis'] = motor_axes[new_value];
-            }
-        },
-
-        current_max_velocity(new_value) {
-            if(new_value != this.motor['max-velocity']) {
-                this.motor['max-velocity'] = new_value;
-            }
-        },
-
-        current_max_soft_limit(new_value) {
-            if(new_value != this.motor['max-soft-limit']) {
-                this.motor['max-soft-limit'] = new_value;
-            }
-        },
-
-        current_min_soft_limit(new_value) {
-            if(new_value != this.motor['min-soft-limit']) {
-                this.motor['min-soft-limit'] = new_value;
-            }
-        },
-
-        current_max_accel(new_value) {
-            if(new_value != this.motor['max-accel']) {
-                this.motor['max-accel'] = new_value;
-            }
-        },
-        
-        current_max_jerk(new_value) {
-            if(new_value != this.motor['max-jerk']) {
-                this.motor['max-jerk'] = new_value;
-            }
-        },
-        
-        current_step_angle(new_value) {
-            if(new_value != this.motor['step-angle']) {
-                this.motor['step-angle'] = new_value;
-            }
-        },
-        
-        current_travel_per_rev(new_value) {
-            if(new_value != this.motor['travel-per-rev']) {
-                this.motor['travel-per-rev'] = new_value;
-            }
-        },
-        
-        current_microsteps(new_value) {
-            if(new_value != this.motor['microsteps']) {
-                this.motor['microsteps'] = new_value;
-            }
-        }
+        // NOTE: do not add `current_xxx` computed props that mirror
+        // controller state vars (`<idx>vm`, `<idx>am`, …) and pair
+        // them with watchers that copy state -> motor config. The
+        // controller streams those vars continuously over the WS;
+        // any watcher that writes them back into
+        // `config.motors[index]` will clobber whatever the user is
+        // typing into the form between websocket ticks. The form
+        // edits config directly; Save (app.js) PUTs it to the
+        // server. The server-side rotary toggle is handled by
+        // refetching config after the PUT, not by watching state.
     },
 
     events: {
@@ -210,45 +126,6 @@ module.exports = {
             }
 
             return templ.hmodes.indexOf(this.motor["homing-mode"]) != -1;
-        },
-
-        syncStateToConfig: function() {
-            // Force sync all state values to motor config
-            // This ensures the UI reflects the current state even if changes happened while component was unmounted
-
-            if(this.state == undefined) {
-                console.log("State is undefined");
-                return;
-            }
-            
-            if (this.state[this.index + 'an'] != this.motor['axis']) {
-                const motor_axes = ["X", "Y", "Z", "A", "B", "C"];
-                this.$set('motor["axis"]', motor_axes[this.state[this.index + 'an']]);
-            }
-            if (this.state[this.index + 'vm'] != this.motor['max-velocity']) {
-                this.$set('motor["max-velocity"]', this.state[this.index + 'vm']);
-            }
-            if (this.state[this.index + 'tm'] != this.motor['max-soft-limit']) {
-                this.$set('motor["max-soft-limit"]', this.state[this.index + 'tm']);
-            }
-            if (this.state[this.index + 'tn'] != this.motor['min-soft-limit']) {
-                this.$set('motor["min-soft-limit"]', this.state[this.index + 'tn']);
-            }
-            if (this.state[this.index + 'am'] != this.motor['max-accel']) {
-                this.$set('motor["max-accel"]', this.state[this.index + 'am']);
-            }
-            if (this.state[this.index + 'jm'] != this.motor['max-jerk']) {
-                this.$set('motor["max-jerk"]', this.state[this.index + 'jm']);
-            }
-            if (this.state[this.index + 'sa'] != this.motor['step-angle']) {
-                this.$set('motor["step-angle"]', this.state[this.index + 'sa']);
-            }
-            if (this.state[this.index + 'tr'] != this.motor['travel-per-rev']) {
-                this.$set('motor["travel-per-rev"]', this.state[this.index + 'tr']);
-            }
-            if (this.state[this.index + 'mi'] != this.motor['microsteps']) {
-                this.$set('motor["microsteps"]', this.state[this.index + 'mi']);
-            }
         }
     }
 };

src/js/orbit.js

@@ -683,12 +683,16 @@ const OrbitControls = function(object, domElement) {
         event.preventDefault();
     }
 
+    // Chrome treats touch/wheel listeners as passive by default,
+    // which prevents OrbitControls.preventDefault() from suppressing
+    // page panning while interacting with the 3D viewer. Pass
+    // {passive: false} on the events that need to call preventDefault.
     scope.domElement.addEventListener("contextmenu", onContextMenu, false);
     scope.domElement.addEventListener("mousedown", onMouseDown, false);
-    scope.domElement.addEventListener("wheel", onMouseWheel, false);
-    scope.domElement.addEventListener("touchstart", onTouchStart, false);
+    scope.domElement.addEventListener("wheel", onMouseWheel, { passive: false });
+    scope.domElement.addEventListener("touchstart", onTouchStart, { passive: false });
     scope.domElement.addEventListener("touchend", onTouchEnd, false);
-    scope.domElement.addEventListener("touchmove", onTouchMove, false);
+    scope.domElement.addEventListener("touchmove", onTouchMove, { passive: false });
     window.addEventListener("keydown", onKeyDown, false);
 
     this.update(); // force an update at start

src/js/path-viewer.js

@@ -101,6 +101,13 @@ module.exports = {
         Vue.nextTick(this.update);
     },
 
+    beforeDestroy: function() {
+        if (this._sizeWatcher) {
+            this._sizeWatcher.disconnect();
+            this._sizeWatcher = null;
+        }
+    },
+
     methods: {
         update: async function() {
             if (!this.webglAvailable) {
@@ -201,6 +208,12 @@ module.exports = {
             }
 
             const dims = this.get_dims();
+            // Skip layouts where the target has no measurable size.
+            // The render loop guard below will not draw frames until
+            // a real size has been observed at least once.
+            if (!(dims.width > 0 && dims.height > 0)) {
+                return;
+            }
 
             this.camera.aspect = dims.width / dims.height;
             this.camera.updateProjectionMatrix();
@@ -274,12 +287,23 @@ module.exports = {
             }
 
             try {
-                // Renderer
-                this.renderer = new THREE.WebGLRenderer({ antialias: true, alpha: true });
+                // Renderer. Use an opaque canvas with a clear color
+                // that matches the page-side gradient so the moment
+                // the canvas is appended (and before the first 3D
+                // frame is drawn) the user does not see a flash from
+                // the page background through transparency.
+                this.renderer = new THREE.WebGLRenderer({
+                    antialias: true,
+                    alpha: false,
+                });
                 this.renderer.setPixelRatio(window.devicePixelRatio);
-                this.renderer.setClearColor(0, 0);
+                this.renderer.setClearColor(0x222222, 1);
+                // Same color on the DOM element itself so the very
+                // first paint (before the WebGL context has cleared)
+                // is dark too.
+                this.renderer.domElement.style.background = "#222222";
+                this.renderer.domElement.style.display = "block";
                 this.target.appendChild(this.renderer.domElement);
-
             } catch (e) {
                 console.log("WebGL not supported: ", e);
                 return;
@@ -333,8 +357,46 @@ module.exports = {
             // Events
             window.addEventListener("resize", this.update_view, false);
 
-            // Start it
-            this.render();
+            // Start the render loop only after the target has a real,
+            // stable size. Without this, the first frame paints into
+            // a 0×0 / collapsed-flex canvas and a second frame paints
+            // again at the right size — visible as a flash on the
+            // very first mount of the Program tab.
+            const startRendering = () => {
+                if (this._rendering) return;
+                this._rendering = true;
+                this.update_view();
+                this.render();
+            };
+
+            const dims = this.get_dims();
+            if (dims.width > 0 && dims.height > 0) {
+                startRendering();
+            } else if (typeof ResizeObserver !== "undefined") {
+                this._sizeWatcher = new ResizeObserver(entries => {
+                    for (const entry of entries) {
+                        const r = entry.contentRect;
+                        if (r.width > 0 && r.height > 0) {
+                            this._sizeWatcher.disconnect();
+                            this._sizeWatcher = null;
+                            startRendering();
+                            return;
+                        }
+                    }
+                });
+                this._sizeWatcher.observe(this.target);
+            } else {
+                // Old browser fallback: poll for a non-zero size.
+                const tick = () => {
+                    const d = this.get_dims();
+                    if (d.width > 0 && d.height > 0) {
+                        startRendering();
+                    } else {
+                        requestAnimationFrame(tick);
+                    }
+                };
+                requestAnimationFrame(tick);
+            }
         },
 
         create_surface_material: function() {
@@ -646,6 +708,14 @@ module.exports = {
                 return;
             }
 
+            // Don't paint frames while the target has no size; this
+            // prevents an initial single-frame clear from painting
+            // before the layout has settled (visible as a dark flash).
+            const dims = this.get_dims();
+            if (!(dims.width > 0 && dims.height > 0)) {
+                return;
+            }
+
             if (this.controls.update() || this.dirty) {
                 this.dirty = false;
                 this.renderer.render(this.scene, this.camera);

src/js/program-mixin.js

@@ -0,0 +1,607 @@
+"use strict";
+
+// Shared data, computed properties and methods that are used by both
+// the Control view (for things like start/stop, run-macro, axis state)
+// and the Program view (RUN/STOP/Upload/Download/Delete + file picker
+// + gcode/path viewers). Splitting these out lets us mount the same
+// behaviour under two top-level routes without duplicating code.
+//
+// The mixin intentionally does *not* require axis-vars; control-view
+// keeps that one to itself.
+
+const api = require("./api");
+const utils = require("./utils");
+
+module.exports = {
+  data: function () {
+    return {
+      mdi: "",
+      last_file: undefined,
+      last_file_time: undefined,
+      toolpath: {},
+      toolpath_progress: 0,
+      history: [],
+      speed_override: 1,
+      feed_override: 1,
+      deleteGCode: false,
+      folder_name: "",
+      edited: false,
+      uploading_files: false,
+      confirmDelete: false,
+      create_folder: false,
+      showGcodeMessage: false,
+      showNoGcodeMessage: false,
+      macrosLoading: false,
+      show_gcodes: false,
+      GCodeNotFound: false,
+      filesUploaded: 0,
+      totalFiles: 0,
+      files_sortby: "By Upload Date",
+      selected_items_to_delete: [],
+      search_query: "",
+      filtered_files: [],
+      selected_folder_index: null,
+    };
+  },
+
+  watch: {
+    "state.line": function () {
+      if (this.mach_state != "HOMING") {
+        this.$broadcast("gcode-line", this.state.line);
+      }
+    },
+
+    "state.selected_time": function () {
+      this.load();
+    },
+  },
+
+  computed: {
+    is_running: function () {
+      return this.mach_state == "RUNNING" || this.mach_state == "HOMING";
+    },
+
+    is_stopping: function () {
+      return this.mach_state == "STOPPING";
+    },
+
+    is_holding: function () {
+      return this.mach_state == "HOLDING";
+    },
+
+    is_ready: function () {
+      return this.mach_state == "READY";
+    },
+
+    is_idle: function () {
+      return this.state.cycle == "idle";
+    },
+
+    // True only while a loaded G-code program is actually being
+    // executed (running, paused/holding, or stopping). Excludes
+    // jogging, homing, probing, MDI commands and other one-off
+    // motion that also leave state.xx == "RUNNING" but must not
+    // swap the jog grid out for the "Now Running" panel.
+    //
+    // Distinguishing signal is state.cycle:
+    //   - "idle"    : nothing happening
+    //   - "jogging" : user-initiated jog
+    //   - "homing"  : home cycle
+    //   - "probing" : probe cycle
+    //   - "mdi"     : single MDI command
+    //   - "running" : an actual loaded program is being run
+    // Only "running" (combined with a selected file) is what we want.
+    is_program_executing: function () {
+      if (!this.state) return false;
+      const xx = this.state.xx;
+      const cycle = this.state.cycle;
+      const isExecState = xx == "RUNNING" || xx == "HOLDING" || xx == "STOPPING";
+      if (!isExecState) return false;
+      // The cycle string narrows it to a real program run; anything
+      // else (jogging / homing / probing / mdi) is a one-off.
+      if (cycle && cycle != "running" && cycle != "idle") return false;
+      return !!this.state.selected;
+    },
+
+    is_paused: function () {
+      return this.is_holding && (this.pause_reason == "User pause" || this.pause_reason == "Program pause");
+    },
+
+    can_mdi: function () {
+      return this.is_idle || this.state.cycle == "mdi";
+    },
+
+    pause_reason: function () {
+      return this.state.pr;
+    },
+
+    plan_time: function () {
+      return this.state.plan_time;
+    },
+
+    plan_time_remaining: function () {
+      if (!(this.is_stopping || this.is_running || this.is_holding)) {
+        return 0;
+      }
+      return this.toolpath.time - this.plan_time;
+    },
+
+    eta: function () {
+      if (this.mach_state != "RUNNING") {
+        return "";
+      }
+      const remaining = this.plan_time_remaining;
+      const d = new Date();
+      d.setSeconds(d.getSeconds() + remaining);
+      return d.toLocaleString();
+    },
+
+    progress: function () {
+      if (!this.toolpath.time || this.is_ready) {
+        return 0;
+      }
+      const p = this.plan_time / this.toolpath.time;
+      return Math.min(1, p);
+    },
+
+    gcode_files: function () {
+      if (!this.state.folder) return [];
+      const list = Array.isArray(this.state.gcode_list) ? this.state.gcode_list : [];
+      const folder = list.find(item => item.name == this.state.folder);
+      if (!folder) return [];
+      const stateFiles = Array.isArray(this.state.files) ? this.state.files : [];
+      const files = (folder.files || [])
+        .filter(item => stateFiles.includes(item.file_name))
+        .map(item => item.file_name);
+      if (this.files_sortby == "A-Z") return files.sort();
+      if (this.files_sortby == "Z-A") return files.sort().reverse();
+      return files;
+    },
+
+    gcode_filtered_files: function () {
+      return this.filtered_files.filter(file =>
+        file.toLowerCase().includes(this.search_query.toLowerCase()));
+    },
+
+    gcode_folders: function () {
+      const list = Array.isArray(this.state.gcode_list) ? this.state.gcode_list : [];
+      return list
+        .map(item => item.name)
+        .filter(element => element !== "default")
+        .sort();
+    },
+  },
+
+  methods: {
+    save_config: async function (config) {
+      try {
+        await api.put("config/save", config);
+        this.$dispatch("update");
+      } catch (error) {
+        console.error("Restore Failed: ", error);
+        alert("Restore failed");
+      }
+    },
+
+    populateFiles(index) {
+      this.selected_folder_index = index;
+      this.filtered_files = this.state.gcode_list[index].files.map(item => item.file_name);
+    },
+
+    send: function (msg) {
+      this.$dispatch("send", msg);
+    },
+
+    toggle_sorting: function () {
+      if (this.files_sortby === "By Upload Date") this.files_sortby = "A-Z";
+      else if (this.files_sortby === "A-Z") this.files_sortby = "Z-A";
+      else if (this.files_sortby === "Z-A") this.files_sortby = "By Upload Date";
+    },
+
+    load: function () {
+      const file_time = this.state.selected_time;
+      const file = this.state.selected;
+      if (this.last_file == file && this.last_file_time == file_time) return;
+
+      // state.files can be undefined briefly after connect, before the
+      // controller has pushed its file list. Skip the existence check
+      // until we have a list to consult.
+      const files = Array.isArray(this.state.files) ? this.state.files : null;
+      if (this.state.selected && files && !files.includes(this.state.selected)) {
+        this.GCodeNotFound = true;
+        return;
+      }
+
+      this.last_file = file;
+      this.last_file_time = file_time;
+
+      this.$broadcast("gcode-load", file);
+      this.$broadcast("gcode-line", this.state.line);
+      this.toolpath_progress = 0;
+      this.load_toolpath(file, file_time);
+    },
+
+    load_toolpath: async function (file, file_time) {
+      this.toolpath = {};
+      if (!file || this.last_file_time != file_time) return;
+
+      this.showGcodeMessage = true;
+
+      while (this.showGcodeMessage) {
+        try {
+          const toolpath = await api.get(`path/${file}`);
+          this.toolpath_progress = toolpath.progress;
+
+          if (toolpath.progress === 1 || typeof toolpath.progress == "undefined") {
+            this.showGcodeMessage = false;
+
+            if (toolpath.bounds) {
+              toolpath.filename = file;
+              this.toolpath_progress = 1;
+              this.toolpath = toolpath;
+
+              const state = this.$root.state;
+              for (const axis of "xyzabc") {
+                Vue.set(state, `path_min_${axis}`, toolpath.bounds.min[axis]);
+                Vue.set(state, `path_max_${axis}`, toolpath.bounds.max[axis]);
+              }
+            }
+          }
+        } catch (error) {
+          console.error(error);
+        }
+      }
+    },
+
+    submit_mdi: function () {
+      this.send(this.mdi);
+      if (!this.history.length || this.history[0] != this.mdi) {
+        this.history.unshift(this.mdi);
+      }
+      this.mdi = "";
+    },
+
+    mdi_start_pause: function () {
+      if (this.state.xx == "RUNNING") this.pause();
+      else if (this.state.xx == "STOPPING" || this.state.xx == "HOLDING") this.unpause();
+      else this.submit_mdi();
+    },
+
+    load_history: function (index) {
+      this.mdi = this.history[index];
+    },
+
+    open_file: function () {
+      utils.clickFileInput("gcode-file-input");
+    },
+
+    open_folder: function () {
+      utils.clickFileInput("gcode-folder-input");
+    },
+
+    edited_folder_name: function (event) {
+      if (event.target.value.trim() != "") {
+        this.$dispatch("folder_name_edited");
+      }
+    },
+
+    update_config: function () {
+      this.config.gcode_list = [...this.state.gcode_list];
+      this.config.non_macros_list = [...this.state.non_macros_list];
+      this.config.macros_list = [...this.state.macros_list];
+      this.config.macros = [...this.state.macros];
+    },
+
+    reset_gcode: function () {
+      this.state.selected = "";
+      this.last_file = "";
+      this.$broadcast("gcode-load", "");
+    },
+
+    upload_gcode: async function (filename, file) {
+      return new Promise((resolve, reject) => {
+        const xhr = new XMLHttpRequest();
+        this.filesUploaded++;
+        if (this.filesUploaded == this.totalFiles) {
+          this.uploading_files = false;
+        }
+        xhr.onload = () => {
+          if (xhr.status >= 200 && xhr.status < 300) resolve("file uploaded");
+          else { console.error("File upload failed:", xhr.statusText); reject("upload failed"); }
+        };
+        xhr.onerror = () => { alert("Upload failed."); reject("upload failed"); };
+        xhr.open("PUT", `/api/file/${encodeURIComponent(filename)}`, true);
+        xhr.send(file);
+      });
+    },
+
+    readFile: function (file) {
+      return new Promise((resolve, reject) => {
+        const reader = new FileReader();
+        reader.onload = () => resolve(reader.result);
+        reader.onerror = error => reject(error);
+        reader.readAsText(file, "utf-8");
+      });
+    },
+
+    validateFiles: async function (files) {
+      const validFiles = [];
+      for (const file of files) {
+        const extension = file.name.split(".").pop().toLowerCase();
+        const validExtensions = ["nc", "ngc", "gcode", "gc"];
+        if (validExtensions.includes(extension)) {
+          validFiles.push(file);
+        } else {
+          alert(`Unsupported file : ${file.name}`);
+          this.filesUploaded++;
+          if (this.filesUploaded == this.totalFiles) {
+            this.uploadFiles = false;
+          }
+        }
+      }
+      return validFiles;
+    },
+
+    uploadValidFiles: async function (files, folderName) {
+      const updatedConfig = { ...this.config };
+
+      for (const file of files) {
+        try {
+          const gcode = await this.readFile(file);
+          await this.upload_gcode(file.name, gcode);
+
+          const isAlreadyPresent = updatedConfig.non_macros_list.some(element => element.file_name === file.name);
+          if (!isAlreadyPresent) {
+            updatedConfig.non_macros_list.push({ file_name: file.name });
+          }
+
+          if (folderName) {
+            const folder = updatedConfig.gcode_list.find(item => item.type == "folder" && item.name == folderName);
+            if (folder) {
+              if (!folder.files.map(item => item.file_name).includes(file.name)) {
+                folder.files.push({ file_name: file.name });
+              }
+            } else {
+              updatedConfig.gcode_list.push({
+                name: folderName,
+                type: "folder",
+                files: [{ file_name: file.name }],
+              });
+            }
+          } else {
+            var folder_to_add = updatedConfig.gcode_list.find(
+              item => item.type == "folder" && item.name == this.state.folder,
+            );
+            if (!folder_to_add) {
+              folder_to_add = updatedConfig.gcode_list.unshift({
+                name: this.state.folder,
+                type: "folder",
+                files: [{ file_name: file.name }],
+              });
+              folder_to_add = updatedConfig.gcode_list[0];
+            }
+            if (!folder_to_add.files.find(item => item.file_name == file.name)) {
+              folder_to_add.files.push({ file_name: file.name });
+            }
+          }
+        } catch (error) {
+          console.warn(`error uploading file : `, error);
+        }
+      }
+      return updatedConfig;
+    },
+
+    upload_files: async function (files, folderName) {
+      this.update_config();
+      const validFiles = await this.validateFiles(files);
+      const updatedConfig = await this.uploadValidFiles(validFiles, folderName);
+      await this.save_config(updatedConfig);
+    },
+
+    upload_file: async function (e) {
+      this.uploading_files = true;
+      this.filesUploaded = 0;
+      const files = e.target.files || e.dataTransfer.files;
+      if (!files.length) return;
+      this.totalFiles = files.length;
+      await this.upload_files(files);
+    },
+
+    create_new_folder: async function () {
+      const folder_name = this.folder_name.trim();
+      if (folder_name != "") {
+        if (this.state.gcode_list.find(item => item.type == "folder" && item.name == folder_name)) {
+          alert("Folder with the same name already exists!");
+          return;
+        }
+        this.update_config();
+        this.config.gcode_list.push({
+          name: folder_name,
+          type: "folder",
+          files: [],
+        });
+        this.state.folder = folder_name;
+        this.edited = false;
+        this.create_folder = false;
+        this.folder_name = "";
+        this.save_config(this.config);
+      }
+    },
+
+    cancel_new_folder: function () {
+      this.create_folder = false;
+      this.folder_name = "";
+    },
+
+    upload_folder: async function (e) {
+      this.uploading_files = true;
+      this.filesUploaded = 0;
+      const files = e.target.files || e.dataTransfer.files;
+      if (!files.length) return;
+      this.totalFiles = files.length;
+      const folderName = files[0].webkitRelativePath.split("/")[0];
+      this.upload_files(files, folderName);
+    },
+
+    delete_current: async function () {
+      if (!this.state.selected) {
+        this.deleteGCode = false;
+        return;
+      }
+      this.update_config();
+
+      this.config.non_macros_list = this.config.non_macros_list.filter(
+        item => !this.selected_items_to_delete.includes(item.file_name),
+      );
+      const folder_to_update = this.config.gcode_list.find(
+        item => item.name == this.config.gcode_list[this.selected_folder_index].name && item.type == "folder",
+      );
+      folder_to_update.files = folder_to_update.files.filter(
+        item => !this.selected_items_to_delete.includes(item.file_name),
+      );
+
+      const exception_list = this.state.macros_list.map(item => item.file_name);
+      let files_to_delete = this.selected_items_to_delete.filter(item => !exception_list.includes(item));
+
+      await api.delete(`file/DINCAIQABiDARixAxiABDIHCAMQABiABDIHCAQQABiABDIH${files_to_delete.toString()}`);
+
+      this.save_config(this.config);
+      this.filtered_files = [];
+      this.search_query = "";
+      this.selected_folder_index = null;
+      this.selected_items_to_delete = [];
+      this.deleteGCode = false;
+    },
+
+    cancel_delete: function () {
+      this.filtered_files = [];
+      this.search_query = "";
+      this.selected_folder_index = null;
+      this.selected_items_to_delete = [];
+      this.deleteGCode = false;
+    },
+
+    delete_all: function () {
+      api.delete("file");
+      this.deleteGCode = false;
+    },
+
+    delete_all_except_macros: async function () {
+      this.update_config();
+      const macrosList = this.state.macros_list.map(item => item.file_name).toString();
+      api.delete(`file/EgZjaHJvbWUqCggBEAAYsQMYgAQyBggAEEUYOTIKCAE${macrosList}`);
+      this.config.non_macros_list = [];
+      this.config.gcode_list = [{ name: "default", type: "folder", files: [] }];
+      this.save_config(this.config);
+      this.state.folder = "default";
+      this.state.selected = "";
+      this.selected_items_to_delete = [];
+      this.deleteGCode = false;
+    },
+
+    delete_folder: async function () {
+      this.update_config();
+      if (this.state.folder && this.state.folder != "default") {
+        const files_to_move = this.config.gcode_list.find(
+          item => item.type == "folder" && item.name == this.state.folder,
+        );
+        if (files_to_move) {
+          const default_folder = this.config.gcode_list.find(item => item.name == "default");
+          default_folder.files = [...default_folder.files, ...files_to_move.files].sort();
+          this.config.gcode_list = this.config.gcode_list.filter(item => item.name != this.state.folder);
+          this.save_config(this.config);
+        }
+      }
+      this.state.folder = "default";
+      this.confirmDelete = false;
+    },
+
+    delete_folder_and_files: async function () {
+      if (!this.state.folder) {
+        this.confirmDelete = false;
+        return;
+      }
+      this.update_config();
+      const selected_folder = this.config.gcode_list.find(
+        item => item.type == "folder" && item.name == this.state.folder,
+      );
+      if (!selected_folder) return;
+
+      const macrosList = this.state.macros_list.map(item => item.file_name);
+      var files_to_delete = selected_folder.files
+        .map(item => item.file_name)
+        .filter(item => !macrosList.includes(item));
+
+      if (selected_folder.name != "default") {
+        this.config.gcode_list = this.config.gcode_list.filter(item => item.name != this.state.folder);
+      } else {
+        selected_folder.files = [];
+      }
+
+      await api.delete(`file/DINCAIQABiDARixAxiABDIHCAMQABiABDIHCAQQABiABDIH${files_to_delete.toString()}`);
+      this.config.non_macros_list = this.config.non_macros_list.filter(
+        item => !files_to_delete.includes(item.file_name),
+      );
+      this.save_config(this.config);
+      this.state.folder = "default";
+      this.confirmDelete = false;
+    },
+
+    start_pause: function () {
+      this.macrosLoading = false;
+      if (this.state.xx == "RUNNING") this.pause();
+      else if (this.state.xx == "STOPPING" || this.state.xx == "HOLDING") this.unpause();
+      else this.start();
+    },
+
+    start:    function () { api.put("start"); },
+    pause:    function () { api.put("pause"); },
+    unpause:  function () { api.put("unpause"); },
+    optional_pause: function () { api.put("pause/optional"); },
+    stop:     function () { api.put("stop"); },
+    step:     function () { api.put("step"); },
+
+    override_feed:  function () { api.put(`override/feed/${this.feed_override}`); },
+    override_speed: function () { api.put(`override/speed/${this.speed_override}`); },
+
+    run_macro: async function (id) {
+      if (this.state.macros[id].file_name == "default") {
+        this.showNoGcodeMessage = true;
+        return;
+      }
+      const file_name = this.state.macros[id].file_name;
+      try {
+        // Selecting a file on the server is a side effect of
+        // GET /api/file/<name>. The macro button used to mutate
+        // state.selected client-side and immediately call start, which
+        // raced the file fetch: if the server hadn't seen the new
+        // selection yet, mach.start() ran whichever file was selected
+        // last. Do it explicitly and await so start always sees the
+        // right file.
+        if (file_name != this.state.selected) {
+          this.state.selected = file_name;
+          // GET /api/file/<name> returns gcode text (not JSON), so use
+          // fetch directly. The server's FileHandler.get sets
+          // state.selected as a side effect; we await the response
+          // before starting so mach.start() reads the right file.
+          const resp = await fetch(
+            `/api/file/${encodeURIComponent(file_name)}`,
+            { cache: "no-cache" }
+          );
+          if (!resp.ok) {
+            throw new Error(`file fetch failed: ${resp.status}`);
+          }
+          await resp.text();
+        }
+        this.load();
+        if (this.state.macros[id].alert == true) {
+          this.macrosLoading = true;
+        } else {
+          await this.start_pause();
+        }
+      } catch (error) {
+        console.warn("Error running macro: ", error);
+      }
+    },
+  },
+};

src/js/program-view.js

@@ -0,0 +1,62 @@
+"use strict";
+
+// Program tab — file management, run/stop, gcode listing and 3D
+// toolpath preview. Reuses the shared mixin (program-mixin) that also
+// powers the legacy bits of control-view; this view does not host the
+// jog grid or the DRO.
+
+module.exports = {
+  template: "#program-view-template",
+  props: ["config", "template", "state"],
+
+  components: {
+    "path-viewer": require("./path-viewer"),
+    "gcode-viewer": require("./gcode-viewer"),
+  },
+
+  data: function () {
+    return {};
+  },
+
+  watch: {
+    "state.metric": {
+      handler: function () {},
+      immediate: true,
+    },
+  },
+
+  computed: {
+    is_kiosk: function () { return !!this.$root.is_kiosk; },
+
+    display_units: {
+      cache: false,
+      get: function () { return this.$root.display_units; },
+      set: function (value) {
+        this.config.settings.units = value;
+        this.$root.display_units = value;
+        this.$dispatch("config-changed");
+      },
+    },
+
+    metric: function () {
+      return this.display_units === "METRIC";
+    },
+
+    mach_state: function () {
+      const cycle = this.state.cycle;
+      const xx = this.state.xx;
+      if (xx != "ESTOPPED" && (cycle == "jogging" || cycle == "homing")) {
+        return cycle.toUpperCase();
+      }
+      return xx || "";
+    },
+
+    can_set_axis: function () { return this.state.cycle == "idle"; },
+  },
+
+  ready: function () {
+    this.load();
+  },
+
+  mixins: [require("./program-mixin")],
+};

src/js/restart-timing.js

@@ -0,0 +1,80 @@
+// Lightweight UI-side restart/cold-load timing.
+//
+// Records a few key marks using performance.now(), then POSTs them to
+// /api/diag/timing/ui once 'ui.first_state' has fired. Disabled by
+// setting window.BBCTRL_TRACE = false before this module is loaded.
+//
+// Marks collected:
+//   script.load    -- this module evaluated
+//   ws.open        -- websocket onopen
+//   ws.first_msg   -- first message from controller
+//   ui.first_state -- first message that contained controller state
+//   window.load    -- window 'load' event
+//
+// Aligning these with /api/diag/timing on the server gives the full
+// picture from systemd start -> bbctrl up -> WS open -> UI rendered.
+"use strict";
+
+const _enabled = typeof window !== "undefined" && window.BBCTRL_TRACE !== false;
+const _t0 = (typeof performance !== "undefined" && performance.now)
+    ? performance.now()
+    : Date.now();
+const _navStart = (typeof performance !== "undefined" && performance.timeOrigin)
+    ? performance.timeOrigin
+    : Date.now();
+
+const marks = [];
+let posted = false;
+
+function _now() {
+    return (typeof performance !== "undefined" && performance.now)
+        ? performance.now() - _t0
+        : Date.now() - _t0;
+}
+
+function mark(name, fields) {
+    if (!_enabled) return;
+    marks.push(Object.assign({ n: name, t: Math.round(_now()) }, fields || {}));
+}
+
+function _post() {
+    if (!_enabled || posted) return;
+    posted = true;
+    const body = JSON.stringify({
+        navStart: _navStart,
+        t0_perf: _t0,
+        href: typeof location !== "undefined" ? location.href : "",
+        ua: typeof navigator !== "undefined" ? navigator.userAgent : "",
+        marks: marks,
+    });
+    try {
+        if (typeof fetch === "function") {
+            fetch("/api/diag/timing/ui", {
+                method: "PUT",
+                headers: { "Content-Type": "application/json" },
+                body: body,
+                keepalive: true,
+            }).catch(() => {});
+        }
+    } catch (e) { /* swallow */ }
+}
+
+// Record window load too; doesn't block posting.
+if (_enabled && typeof window !== "undefined") {
+    window.addEventListener("load", () => mark("window.load"));
+}
+
+mark("script.load");
+
+module.exports = {
+    enabled: _enabled,
+    mark: mark,
+    onWsOpen: () => mark("ws.open"),
+    onWsFirstMessage: () => mark("ws.first_msg"),
+    onFirstState: () => {
+        mark("ui.first_state");
+        // Defer slightly so any synchronous render finishes first.
+        setTimeout(_post, 100);
+    },
+    flush: _post,
+};

src/js/settings-shell-view.js

@@ -0,0 +1,175 @@
+"use strict";
+
+// Wrapper that adds a left-rail navigator around the settings family
+// of views (Settings, Admin General, Admin Network, Tool, IO, Motor,
+// Macros, Help, Cheat Sheet). The inner view is selected by the URL
+// hash (parsed in app.js) and exposed as $root.sub_tab.
+
+// Vue 1 has trouble making child components reactive to `$root.sub_tab`
+// changes (whether via computed, watch, or prop binding through
+// `<component :is>`). The shell instead listens to `hashchange`
+// directly and parses the hash itself, mirroring app.js's logic, then
+// keeps a local data prop `sub` that the template binds to. This is
+// the only path that updates the rail's `:class` reactively.
+module.exports = {
+  template: "#settings-shell-view-template",
+  props: ["config", "template", "state", "index"],
+
+  components: {
+    "settings-view-inner":     require("./settings-view"),
+    "admin-general-view":      require("./admin-general-view"),
+    "admin-network-view":      require("./admin-network-view"),
+    "motor-view":              require("./motor-view"),
+    "tool-view":               require("./tool-view"),
+    "io-view":                 require("./io-view"),
+    "macros-view":             require("./macros"),
+    "help-view":               require("./help-view"),
+    "a-axis-view":             require("./a-axis-view"),
+    "cheat-sheet-view": {
+      template: "#cheat-sheet-view-template",
+      data: function () {
+        return { showUnimplemented: false };
+      },
+    },
+  },
+
+  data: function () {
+    return {
+      sub: this.$root.sub_tab || "settings",
+      ridx: this.$root.index,  // local copy of the motor index
+      // Whether the controller config has streamed in. The Svelte
+      // settings views crash on first paint with the placeholder
+      // config (settings.units / settings.easy-adapter / motion.*
+      // are all undefined). Gate the inner mount on this flag.
+      config_ready: false,
+      rail_items: [
+        { sub: "settings",       href: "#settings",       icon: "fa-display",                  label: "Display & Units" },
+        { sub: "probing",        href: "#probing",        icon: "fa-bullseye",                 label: "Probing" },
+        { sub: "gcode",          href: "#gcode",          icon: "fa-code",                     label: "G-code & Motion" },
+        { sub: "macros",         href: "#macros",         icon: "fa-keyboard",                 label: "Macros" },
+        { sub: "cheat-sheet",    href: "#cheat-sheet",    icon: "fa-book",                     label: "G-code Cheat Sheet" },
+        { sub: "admin-network",  href: "#admin-network",  icon: "fa-network-wired",            label: "Network" },
+        { sub: "admin-general",  href: "#admin-general",  icon: "fa-shield-halved",            label: "General / Firmware" },
+        { sub: "tool",           href: "#tool",           icon: "fa-bolt",                     label: "Spindle & Tool" },
+        { sub: "io",             href: "#io",             icon: "fa-plug",                     label: "I/O" },
+        { section: "Motors" },
+        { sub: "motor", motor: 0, href: "#motor:0", icon: "fa-arrows-up-down-left-right", label: "Motor 0" },
+        { sub: "motor", motor: 1, href: "#motor:1", icon: "fa-arrows-up-down-left-right", label: "Motor 1" },
+        { sub: "motor", motor: 2, href: "#motor:2", icon: "fa-arrows-up-down-left-right", label: "Motor 2" },
+        { sub: "motor", motor: 3, href: "#motor:3", icon: "fa-arrows-up-down-left-right", label: "Motor 3" },
+        // Auxiliary axis (auxcnc ESP32 - exposed to gplan as A).
+        // Mounts the AAxisSettings Svelte component on its own page.
+        { sub: "a-axis", href: "#a-axis", icon: "fa-arrows-up-down", label: "A Axis" },
+        { section: " " },
+        { sub: "help",           href: "#help",           icon: "fa-circle-question", label: "Help" },
+      ],
+    };
+  },
+
+  ready: function () {
+    this._onHash = () => this.refresh_from_hash();
+    window.addEventListener("hashchange", this._onHash);
+    this.refresh_from_hash();
+    this._configPoll = setInterval(() => {
+      const c = this.$root && this.$root.config;
+      const ready = !!(c && c.full_version && c.full_version !== "<loading>"
+        && c.settings && typeof c.settings === "object");
+      if (ready !== this.config_ready) this.config_ready = ready;
+    }, 200);
+  },
+
+  attached: function () {
+    // Vue 1 fires `attached` whenever the component is inserted into
+    // the DOM (which happens on every route change because the outer
+    // <component :is> recreates the instance). Re-bind the listener
+    // here so it works even after detach/attach cycles.
+    if (!this._onHash) {
+      this._onHash = () => this.refresh_from_hash();
+    }
+    window.addEventListener("hashchange", this._onHash);
+    this.refresh_from_hash();
+  },
+
+  detached: function () {
+    if (this._onHash) {
+      window.removeEventListener("hashchange", this._onHash);
+    }
+  },
+
+  beforeDestroy: function () {
+    if (this._onHash) {
+      window.removeEventListener("hashchange", this._onHash);
+    }
+    if (this._configPoll) clearInterval(this._configPoll);
+  },
+
+  methods: {
+    refresh_from_hash: function () {
+      const hash = location.hash.substr(1) || "settings";
+      const parts = hash.split(":");
+      this.sub  = parts[0] || "settings";
+      this.ridx = parts[1] !== undefined ? parts[1] : -1;
+    },
+
+    is_active: function (item) {
+      if (!item || item.section) return false;
+      if (item.sub !== this.sub) return false;
+      if (item.sub === "motor") {
+        return "" + item.motor === "" + this.ridx;
+      }
+      return true;
+    },
+
+    on_rail_click: function (item, ev) {
+      if (!item) return;
+      // Always preventDefault on rail clicks. Letting the browser
+      // anchor-scroll to <div id="settings"> etc. inside .app-body
+      // can pull the .app-head out of view; we drive navigation
+      // ourselves through location.hash and our hashchange handler.
+      if (ev && ev.preventDefault) ev.preventDefault();
+
+      if (item.anchor) {
+        // Soft-link rail items use a #settings hash plus an in-page
+        // anchor scroll once the Svelte page has mounted. We scroll
+        // ONLY the .settings-content overflow container by setting
+        // its scrollTop directly — element.scrollIntoView() walks all
+        // ancestor scroll containers and can tug the .app-body / html
+        // layout, which under tablet mode pulls the fixed header out
+        // of view.
+        if (location.hash !== item.href) location.hash = item.href;
+        this._a_axis_focus = (item.sub === "a-axis");
+        const reset = () => {
+          // Force any inadvertent ancestor scroll back to 0 before
+          // we move .settings-content explicitly.
+          window.scrollTo(0, 0);
+          const body = document.querySelector(".app-body");
+          if (body) body.scrollTop = 0;
+          document.documentElement.scrollTop = 0;
+        };
+        setTimeout(() => {
+          reset();
+          const el = document.getElementById(item.anchor);
+          const scroller = document.querySelector(".settings-content");
+          if (el && scroller) {
+            const elTop = el.getBoundingClientRect().top;
+            const scTop = scroller.getBoundingClientRect().top;
+            scroller.scrollTop = scroller.scrollTop + (elTop - scTop) - 12;
+          }
+          // Re-assert ancestor scroll = 0 in case the assignment above
+          // moved things.
+          requestAnimationFrame(reset);
+        }, 320);
+      } else {
+        this._a_axis_focus = false;
+        if (location.hash !== item.href) location.hash = item.href;
+        // Reset .app-body scroll so each route starts at the top.
+        const body = document.querySelector(".app-body");
+        if (body) body.scrollTop = 0;
+      }
+    },
+
+    showShutdownDialog: function () {
+      SvelteComponents.showDialog("Shutdown");
+    },
+  },
+};

src/js/settings-view.js

@@ -1,14 +1,60 @@
+// V09 wraps the legacy Svelte SettingsView and filters its big page
+// down to a single rail section so each rail item shows only the
+// relevant controls. The Svelte component is left untouched (it is
+// shared with the legacy UI) — we just hide the `<h2>` and `<fieldset>`
+// elements whose `data-sec` does not match the active section.
+
 module.exports = {
     template: "#settings-view-template",
 
-    attached: function() {
+    props: {
+        // "display" | "probing" | "gcode". Default is "display" which
+        // keeps the rail's "Display & Units" item working unchanged.
+        section: { default: "display" },
+    },
+
+    attached: function () {
         this.svelteComponent = SvelteComponents.createComponent(
             "SettingsView",
             document.getElementById("settings")
         );
+        // Defer one tick so Svelte has rendered the section markup.
+        setTimeout(() => this.apply_section_filter(), 0);
     },
 
-    detached: function() {
-        this.svelteComponent.$destroy();
-    }
+    detached: function () {
+        if (this.svelteComponent) this.svelteComponent.$destroy();
+    },
+
+    watch: {
+        section: function () {
+            this.apply_section_filter();
+        },
+    },
+
+    methods: {
+        apply_section_filter: function () {
+            const root = document.getElementById("settings");
+            if (!root) return;
+            const want = this.section || "display";
+            // Hide every section block that does not match.
+            root.querySelectorAll("[data-sec]").forEach(el => {
+                el.style.display = el.dataset.sec === want ? "" : "none";
+            });
+            // Hide the global <h1>Settings</h1> on subsections so the
+            // page reads as a focused panel.
+            const h1 = root.querySelector(".settings-view > h1");
+            if (h1) {
+                if (want === "display") {
+                    h1.textContent = "Display & Units";
+                } else if (want === "probing") {
+                    h1.textContent = "Probing";
+                } else if (want === "gcode") {
+                    h1.textContent = "G-code & Motion";
+                } else {
+                    h1.textContent = "Settings";
+                }
+            }
+        },
+    },
 };

src/pug/index.pug

@@ -8,9 +8,8 @@ html(lang="en")
 
 
     style: include ../static/css/pure-min.css
-    style: include ../static/css/side-menu.css
 
-    style: include ../static/css/font-awesome.min.css
+    style: include ../static/css/fa6.min.css
     style: include ../static/css/Audiowide.css
     style: include ../static/css/clusterize.css
     style: include ../svelte-components/node_modules/svelte-material-ui/bare.css
@@ -19,103 +18,171 @@ html(lang="en")
     style: include:stylus ../stylus/style.styl
 
   body(v-cloak)
+    // Tablet (kiosk) mode — pins the .app-shell to 1920x1080 and
+    // scales it to fit the actual viewport so the UI always looks
+    // exactly like the 10.8" 1920x1080 portable monitor.
+    //
+    // Toggle:  ?tablet=1   to enable
+    //          ?tablet=0   to disable
+    // Sticky in localStorage; once set, no querystring is needed.
+    script.
+      (function () {
+        try {
+          var p = new URLSearchParams(location.search);
+          if (p.has("tablet")) {
+            var on = p.get("tablet") !== "0" && p.get("tablet") !== "false";
+            localStorage.setItem("ui-tablet-mode", on ? "1" : "0");
+          }
+          if (localStorage.getItem("ui-tablet-mode") === "1") {
+            document.documentElement.classList.add("tablet-mode");
+          }
+          function fit() {
+            if (!document.documentElement.classList.contains("tablet-mode")) return;
+            var s = Math.min(window.innerWidth / 1920, window.innerHeight / 1080);
+            document.documentElement.style.setProperty("--tablet-scale", s);
+          }
+          fit();
+          window.addEventListener("resize", fit);
+
+          // Kiosk mode: when the UI is loaded by the controller's
+          // own onboard browser (Chromium pointing at localhost on
+          // the Pi 3B at 1366x768), apply a tighter layout that
+          // packs the V09 UI into the smaller, slower display.
+          // Override with ?kiosk=0 to force the desktop layout.
+          if (p.has("kiosk")) {
+            var k = p.get("kiosk") !== "0" && p.get("kiosk") !== "false";
+            localStorage.setItem("ui-kiosk-mode", k ? "1" : "0");
+          }
+          var stored = localStorage.getItem("ui-kiosk-mode");
+          var auto = location.hostname === "localhost"
+              || location.hostname === "127.0.0.1"
+              || location.hostname === "::1";
+          if (stored === "1" || (stored !== "0" && auto)) {
+            document.documentElement.classList.add("kiosk-mode");
+          }
+        } catch (_e) {}
+      })();
+
     #svelte-dialog-host
 
     #overlay(v-if="status != 'connected'")
       span {{status}}
-    
-    #layout
-      a#menuLink.menu-link(href="#menu"): span
 
-      #menu
-        button.save.pure-button.button-success(:disabled="!modified",
-          @click="save") Save
+    .app-shell
+      header.app-head
+        .brand-blk
+          .brand-logo
+          .brand-name ONEFINITY
 
-        .pure-menu
-          ul.pure-menu-list
-            li.pure-menu-heading
-              a.pure-menu-link(href="#control") Control
+        nav.tabs-host(role="tablist")
+          a.ktab(:class="{active: top_tab === 'control'}", href="#control",
+            title="Jog, DRO, macros")
+            .fa.fa-gamepad
+            span Control
+          a.ktab(:class="{active: top_tab === 'program'}", href="#program",
+            title="Run programs, files, toolpath preview")
+            .fa.fa-list-ol
+            span Program
+          a.ktab(:class="{active: top_tab === 'console'}", href="#console",
+            title="MDI, messages, indicators")
+            .fa.fa-terminal
+            span Console
+            span.ktab-badge(v-if="messages_count") {{messages_count}}
+          a.ktab(:class="{active: top_tab === 'settings'}", href="#settings",
+            title="Configuration, network, macros")
+            .fa.fa-sliders
+            span Settings
 
-            li.pure-menu-heading
-              a.pure-menu-link(href="#macros") Macros
+        .head-spacer
 
-            li.pure-menu-heading
-              a.pure-menu-link(href="#settings") Settings
+        .sys-btn(@click.stop="toggle_sys_popover", :class="{open: sys_open}")
+          span.pip(:class="sys_class")
+          span.sys-text {{sys_summary}}
+          .fa.fa-chevron-down
 
-            li.pure-menu-heading
-              a.pure-menu-link(href="#motor:0") Motors
+        .pi-temp-warning(v-if="80 <= state.rpi_temp",
+          title="Raspberry Pi temperature too high.")
+          .fa.fa-temperature-full
 
-            li.pure-menu-item(v-for="motor in config.motors")
-              a.pure-menu-link(:href="'#motor:' + $index") Motor {{$index}}
+        span.state-badge(:class="state_class", :title="mach_state_full")
+          span.dot
+          span {{state_label}}
 
-            li.pure-menu-heading
-              a.pure-menu-link(href="#tool") Tool
+        .estop(:class="{active: state.es}")
+          estop(@click="estop")
 
-            li.pure-menu-heading
-              a.pure-menu-link(href="#io") I/O
-
-            li.pure-menu-heading
-              a.pure-menu-link(href="#admin-general") Admin
-
-            li.pure-menu-item
-              a.pure-menu-link(href="#admin-general") General
-
-            li.pure-menu-item
-              a.pure-menu-link(href="#admin-network") Network
-
-            li.pure-menu-heading
-              a.pure-menu-link(href="#cheat-sheet") Cheat Sheet
-
-            li.pure-menu-heading
-              a.pure-menu-link(href="#help") Help
-              
-            button.pure-button.pure-button-primary(@click="showShutdownDialog", style="width: 100%")
-              .fa.fa-power-off              
-
-      #main
-        .nav-header
-          .brand
-            img(src="/images/onefinity_logo.png")
-            .version
-              div  Version: v{{config.full_version}}
-              div  IP Address: {{config.ip}}
-              div  WiFi: {{config.wifiName}}
-            a.upgrade-link(v-if="show_upgrade()", href="#admin-general")
-                | Upgrade to v{{latestVersion}}
-                .fa.fa-exclamation-circle.upgrade-attention(v-if="show_upgrade()")
-
-          .pi-temp-warning
-            .fa.fa-thermometer-full(class="error",
-              v-if="80 <= state.rpi_temp",
-              title="Raspberry Pi temperature too high.")
-
-          .easy-adapter(v-if="is_easy_adapter_active")
-            .round-dot
-            div.easy-adapter-text Easy Adapter
-          
-          .whitespace
-
-          div
-            button.rotary-button(:disabled="!enable_rotary", :class="is_rotary_active && 'active'", @click="showSwitchRotaryModeDialog")
-              img(src="/images/rotary.svg", alt="rotary", :style="is_rotary_active ? 'width:90%;' : 'width:85%;'")
-            div.rotary-text Rotary
-
-          .video(title="Plug camera into USB.\n" +
-            "Left click to toggle video size.\n" +
-            "Right click to toggle crosshair.", @click="toggle_video",
-            @contextmenu="toggle_crosshair", :class="video_size")
+        // System popover (chip-soup destination)
+        .sys-popover(v-if="sys_open", @click.stop="")
+          .sp-row
+            .sp-icon: .fa.fa-microchip
+            .sp-text
+              .sp-label Firmware
+              .sp-val v{{config.full_version}}
+            a.sp-act(v-if="show_upgrade()", href="#admin-general")
+              | Upgrade to v{{latestVersion}}
+              .fa.fa-circle-exclamation.upgrade-attention
+          .sp-row
+            .sp-icon: .fa.fa-network-wired
+            .sp-text
+              .sp-label IP Address
+              .sp-val {{config.ip}}
+          .sp-row
+            .sp-icon: .fa.fa-wifi(:class="{'sp-warn': config.wifiName === 'not connected'}")
+            .sp-text
+              .sp-label WiFi
+              .sp-val {{config.wifiName}}
+            a.sp-act(href="#admin-network", @click="sys_open=false") Configure
+          .sp-row(v-if="enable_rotary")
+            .sp-icon: img(src="/images/rotary.svg", alt="rotary")
+            .sp-text
+              .sp-label Rotary
+              .sp-val {{is_rotary_active ? 'Active' : 'Inactive'}}
+            button.sp-act(@click="showSwitchRotaryModeDialog")
+              | {{is_rotary_active ? 'Disable' : 'Enable'}}
+          .sp-row(v-if="is_easy_adapter_active")
+            .sp-icon: .fa.fa-puzzle-piece
+            .sp-text
+              .sp-label Easy Adapter
+              .sp-val Active
+          .sp-row.video-row
+            .sp-icon: .fa.fa-video
+            .sp-text
+              .sp-label Camera
+              .sp-val {{has_camera ? 'Live' : 'Plug camera into USB'}}
+            .sp-act(v-if="has_camera", @click="toggle_video")
+              | {{video_size === 'small' ? 'Enlarge' : 'Shrink'}}
+          .video(v-if="sys_open && has_camera", title="Camera feed",
+            @click="toggle_video", @contextmenu="toggle_crosshair",
+            :class="video_size")
             .crosshair(v-if="crosshair")
               .vertical
               .horizontal
               .box
-            img(src="/api/video")
+            img(src="/api/video", @error="has_camera=false")
+          .sp-foot
+            button.sp-shutdown(@click="showShutdownDialog")
+              .fa.fa-power-off
+              | &nbsp;Shutdown
+            button.sp-save(:disabled="!modified", @click="save")
+              .fa.fa-save
+              | &nbsp;Save{{modified ? '*' : ''}}
 
-          .estop(:class="{active: state.es}")
-            estop(@click="estop")
-
-        .content(class="{{currentView}}-view")
-          component(:is="currentView + '-view'", :index="index",
-            :config="config", :template="template", :state="state", keep-alive)
+      // Routed view. We keep instances alive across tab swaps so:
+      //   - The Program tab's WebGL <path-viewer> canvas does not
+      //     get destroyed and recreated each time (which caused a
+      //     dark flash as the GL context cleared the new canvas
+      //     before its first frame).
+      //   - The Program tab's clusterize.js gcode list does not
+      //     re-virtualize from scratch on every visit.
+      //   - The Settings shell's child Svelte components stay
+      //     mounted, preserving any in-flight form state.
+      // The settings-shell handles its own inner v-if cascade so
+      // the Vue 1 reactivity quirk that motivated removing
+      // keep-alive earlier no longer applies here.
+      .app-body
+        component(:is="currentView + '-view'", :index="index",
+          :config="config", :template="template", :state="state",
+          :sub-tab="sub_tab", keep-alive)
 
     message.error-message(:show.sync="errorShow")
       div(slot="header")

src/pug/templates/a-axis-view.pug

@@ -0,0 +1,4 @@
+script#a-axis-view-template(type="text/x-template")
+  #a-axis-page
+    h1 A Axis (auxcnc)
+    #a-axis-mount

src/pug/templates/console-view.pug

@@ -0,0 +1,67 @@
+script#console-view-template(type="text/x-template")
+  .console-page
+    .console-card
+      .ptab-bar
+        button.ptab(:class="{active: sub === 'mdi'}", @click="select_sub('mdi')")
+          .fa.fa-keyboard
+          |  MDI
+        button.ptab(:class="{active: sub === 'messages'}", @click="select_sub('messages')")
+          .fa.fa-comment-dots
+          |  Messages
+          span.ptab-badge(v-if="unread_messages") {{unread_messages}}
+        button.ptab(:class="{active: sub === 'indicators'}", @click="select_sub('indicators')")
+          .fa.fa-bell
+          |  Indicators
+
+      // ----- MDI -----
+      .mdi-pane(v-show="sub === 'mdi'")
+        .mdi-input
+          span.prompt G>
+          input(type="text", v-model="mdi", :disabled="!can_mdi",
+            @keyup.enter="submit_mdi", placeholder="enter a G-code command…")
+          button.mdi-send(:disabled="!can_mdi || !mdi", @click="submit_mdi")
+            .fa.fa-paper-plane
+            |  SEND
+        .mdi-keys
+          button.mkey(@click="prepend('G0 ')") G0
+          button.mkey(@click="prepend('G1 ')") G1
+          button.mkey(@click="prepend('G2 ')") G2
+          button.mkey(@click="prepend('G3 ')") G3
+          button.mkey(@click="prepend('G28 ')") G28
+          button.mkey(@click="prepend('G92 ')") G92
+          button.mkey(@click="prepend('M3 ')") M3
+          button.mkey(@click="prepend('M5 ')") M5
+          button.mkey(@click="append('X')") X
+          button.mkey(@click="append('Y')") Y
+          button.mkey(@click="append('Z')") Z
+          button.mkey(@click="append('W')") W
+          button.mkey(@click="append('F')") F
+          button.mkey(@click="append('S')") S
+          button.mkey.clear(@click="mdi = ''") CLEAR
+          button.mkey.send(:disabled="!can_mdi || !mdi", @click="submit_mdi") SEND ↵
+
+        em Machine units: #[strong {{mach_units}}]. G20/G21 to switch.
+
+        .mdi-history(:class="{placeholder: !history.length}")
+          span.mdi-empty(v-if="!history.length") MDI history will display here.
+          .h-row(v-for="item in history", @click="load_history($index)",
+            track-by="$index")
+            span.h-cmd {{item}}
+            span.h-status ↻
+
+      // ----- Messages -----
+      .messages-pane(v-show="sub === 'messages'")
+        .msg-empty(v-if="!$root.messages_log.length")
+          .fa.fa-circle-check
+          |  No messages.
+        .msg(v-for="m in $root.messages_log",
+          :class="m.level === 'warning' ? 'warn' : 'info'", track-by="$index")
+          .mi
+            .fa(:class="m.level === 'warning' ? 'fa-triangle-exclamation' : 'fa-circle-info'")
+          div
+            .mtitle {{m.text}}
+            .mtime ID {{m.id}}
+
+      // ----- Indicators -----
+      .indicators-pane(v-show="sub === 'indicators'")
+        indicators(:state="state", :template="template")

src/pug/templates/control-view.pug

@@ -1,475 +1,344 @@
 script#control-view-template(type="text/x-template")
-  #control
+  .control-page
+    // ----- Modal dialogs (kept verbatim from legacy) -----
     message(:show.sync="showGcodeMessage")
       h3(slot="header") Processing New File
-
       div(slot="body")
         h3 Please wait..
         p Simulating GCode to check for errors, calculate ETA and generate 3D view.
-        
       div(slot="footer")
         label Simulating {{(toolpath_progress || 0) | percent}}
-    
+
     message(:show.sync="showNoGcodeMessage")
-        h3(slot="header") GCode Not Set
-        div(slot="body")
-            p Configure the GCode for the selected macro to use it
-            
-        div(slot="footer")
-          button.pure-button(@click="showNoGcodeMessage=false") OK
+      h3(slot="header") GCode Not Set
+      div(slot="body")
+        p Configure the GCode for the selected macro to use it
+      div(slot="footer")
+        button.pure-button(@click="showNoGcodeMessage=false") OK
 
     message(:show.sync="macrosLoading")
-        h3(slot="header") Run Macro?
-        div(slot="body")
-            p 
-              | The macro file 
-              strong {{state.selected}}
-              |  is being loaded.
-            
-        div(slot="footer")
-          button.pure-button(@click="macrosLoading=false") Cancel
-          button.pure-button.pure-button-primary(@click="start_pause") Run
-    
+      h3(slot="header") Run Macro?
+      div(slot="body")
+        p
+          | The macro file
+          strong  {{state.selected}}
+          |  is being loaded.
+      div(slot="footer")
+        button.pure-button(@click="macrosLoading=false") Cancel
+        button.pure-button.pure-button-primary(@click="start_pause") Run
+
     message(:show.sync="GCodeNotFound")
       h3(slot="header") File not found
       div(slot="body")
-          p It seems like the file you selected cannot be found. Try uploading again.
+        p It seems like the file you selected cannot be found. Try uploading again.
       div(slot="footer")
-        button.pure-button.button-error(@click="GCodeNotFound=false")
-          | OK
-    
+        button.pure-button.button-error(@click="GCodeNotFound=false") OK
+
     message(:show.sync="show_probe_dialog")
-      h3(slot="header") Probe Rotary
+      h3(slot="header") Choose probe type
       div(slot="body")
+        p Pick which probe routine to run.
         button.pure-button(:class="state['pw'] ? '' : 'load-on'", @click="showProbeDialog('xyz')") Probe XYZ
         button.pure-button(:class="state['pw'] ? '' : 'load-on'", @click="showProbeDialog('z')") Probe Z
       div(slot="footer")
         button.pure-button(@click="show_probe_dialog=false") Cancel
 
+    // ----- Main grid: jog | (DRO + status strip) -----
+    .control-grid
 
-    table(style="table-layout: fixed; width: 100%;")
-      tr(style="height: fit-content;")
-        td(style="white-space: nowrap; width: 410px;", rowspan="2")
-          table.control-buttons(table-layout="fixed")
-            colgroup
-               col(style="width:100px")
-               col(style="width:100px")
-               col(style="width:100px")
-               col(style="width:100px")
-            tr
-              td(style="height:100px",align="center")
-                button(@click="jog_fn(-1,1,0,0)")
-                  .fa.fa-arrow-right(style="transform: rotate(-135deg);")
-              td(style="height:100px",align="center")
-                button(@click="jog_fn(0,1,0,0)") Y+
-              td(style="height:100px",align="center")
-                button(@click="jog_fn(1,1,0,0)")
-                  .fa.fa-arrow-right(style="transform: rotate(-45deg);")
-              td(style="height:100px",align="center")
-                button(,@click="jog_fn(0,0,1,0)") Z+
-            tr
-              td(style="height:100px",align="center")
-                button(@click="jog_fn(-1,0,0,0)") X-
-              td(style="height:100px",align="center")
-                button(@click="showMoveToZeroDialog('xy')")
-                  | XY
-                  br 
-                  | Origin
-              td(style="height:100px",align="center")
-                button(@click="jog_fn(1,0,0,0)") X+
-              td(style="height:100px",align="center")
-                button(@click="showMoveToZeroDialog('z')") 
-                  | Z
-                  br
-                  | Origin
-            tr
-              td(style="height:100px",align="center")
-                button(@click="jog_fn(-1,-1,0,0)")
-                  .fa.fa-arrow-right(style="transform: rotate(135deg);")
-              td(style="height:100px",align="center")
-                button(@click="jog_fn(0,-1,0,0)") Y-
-              td(style="height:100px",align="center")
-                button(@click="jog_fn(1,-1,0,0)")
-                  .fa.fa-arrow-right(style="transform: rotate(45deg);")
-              td(style="height:100px",align="center")
-                button(@click="jog_fn(0,0,-1,0)") Z-
-            tr
-              td(style="height:100px",align="center")
-                button(:style="getJogIncrStyle('fine')", @click="jog_incr = 'fine'")
-                  span {{jog_incr_amounts[display_units].fine}}#[span.jog-units {{metric ? 'mm' : 'in'}}]
-              td(style="height:100px",align="center")
-                button(:style="getJogIncrStyle('small')", @click="jog_incr = 'small'")
-                  span {{jog_incr_amounts[display_units].small}}#[span.jog-units {{metric ? 'mm' : 'in'}}]
-              td(style="height:100px",align="center")
-                button(:style="getJogIncrStyle('medium')", @click="jog_incr = 'medium'")
-                  span {{jog_incr_amounts[display_units].medium}}#[span.jog-units {{metric ? 'mm' : 'in'}}]
-              td(style="height:100px",align="center")
-                button(:style="getJogIncrStyle('large')", @click="jog_incr = 'large'")
-                  span {{jog_incr_amounts[display_units].large}}#[span.jog-units {{metric ? 'mm' : 'in'}}]
+      // ===== JOG =====
+      // Hidden only while a G-code program is running / paused /
+      // stopping. Jogging / homing / MDI moves do not hide it.
+      .jog-card(v-if="!is_program_executing")
+        .jog-head
+          .jog-title
+            | Jog
+            span.step-pre  · step
+            span.step  {{jog_incr_amounts[display_units][jog_incr]}}#[span.unit {{metric ? 'mm' : 'in'}}]
+          .step-seg
+            button(:class="{active: jog_incr === 'fine'}",   @click="jog_incr = 'fine'")
+              | {{jog_incr_amounts[display_units].fine}}
+            button(:class="{active: jog_incr === 'small'}",  @click="jog_incr = 'small'")
+              | {{jog_incr_amounts[display_units].small}}
+            button(:class="{active: jog_incr === 'medium'}", @click="jog_incr = 'medium'")
+              | {{jog_incr_amounts[display_units].medium}}
+            button(:class="{active: jog_incr === 'large'}",  @click="jog_incr = 'large'")
+              | {{jog_incr_amounts[display_units].large}}
 
-            tr(v-if="state['2an'] == 3")
-              td(style="height:100px", align="center", colspan="1")
-                button(@click="show_probe_dialog=true")
-                  | Probe
-                  br
-                  | Rotary
+        .jog-grid
+          // Row 1
+          button.jbtn.dir(@click="jog_fn(-1, 1, 0, 0)", title="X- Y+")
+            .fa.fa-arrow-up.ico(style="transform: rotate(-45deg)")
+          button.jbtn(@click="jog_fn(0, 1, 0, 0)") Y+
+          button.jbtn.dir(@click="jog_fn(1, 1, 0, 0)", title="X+ Y+")
+            .fa.fa-arrow-up.ico(style="transform: rotate(45deg)")
+          button.jbtn(@click="jog_fn(0, 0, 1, 0)") Z+
 
-              td(style="height:100px", align="center", colspan="1")
-                button(@click="jog_fn(0,0,0,-1)", style="display: grid;justify-content: center;align-items: center;padding: 14px;")
-                  | A-
-                  .fa.fa-rotate-left
-              
-              td(style="height:100px", align="center", colspan="1")
-                button(@click="showMoveToZeroDialog('a')")
-                  | A
-                  br
-                  | Origin
+          // Row 2
+          button.jbtn(@click="jog_fn(-1, 0, 0, 0)") X−
+          button.jbtn(@click="showMoveToZeroDialog('xy')")
+            span.lbl XY
+            span Origin
+          button.jbtn(@click="jog_fn(1, 0, 0, 0)") X+
+          button.jbtn(@click="showMoveToZeroDialog('z')")
+            span.lbl Z
+            span Origin
 
-              td(style="height:100px", align="center", colspan="1")
-                button(@click="jog_fn(0,0,0,1)", style="display: grid;justify-content: center;align-items: center;padding: 14px;")
-                  | A+
-                  .fa.fa-rotate-right
+          // Row 3
+          button.jbtn.dir(@click="jog_fn(-1, -1, 0, 0)", title="X- Y-")
+            .fa.fa-arrow-down.ico(style="transform: rotate(45deg)")
+          button.jbtn(@click="jog_fn(0, -1, 0, 0)") Y−
+          button.jbtn.dir(@click="jog_fn(1, -1, 0, 0)", title="X+ Y-")
+            .fa.fa-arrow-down.ico(style="transform: rotate(-45deg)")
+          button.jbtn(@click="jog_fn(0, 0, -1, 0)") Z−
 
-            tr(v-else)
-              td(style="height:100px", align="center", colspan="2")
-                button(:class="state['pw'] ? '' : 'load-on'",
-                  style="height:100px;width:200px",
-                  @click="showProbeDialog('xyz')")
-                  | Probe XYZ
+          // Row 4 — A axis (the auxcnc-driven external axis) when enabled.
+          //   A-  |  A+  |  Probe XYZ  |  Probe Z
+          // "Home A" lives in the DRO table's actions column on the
+          // right, so it doesn't need a tile here. The legacy w.enabled
+          // gate is kept so older installs (where the auxcnc axis still
+          // appears as W via the side-channel) keep working.
+          template(v-if="w.enabled || a.enabled")
+            button.jbtn(@click="aux_jog_incr(-1)",
+              :disabled="!(w.enabled || a.enabled)")
+              .fa.fa-arrow-down.ico
+              span.lbl A−
+            button.jbtn(@click="aux_jog_incr(+1)",
+              :disabled="!(w.enabled || a.enabled)")
+              .fa.fa-arrow-up.ico
+              span.lbl A+
+            button.jbtn(@click="showProbeDialog('xyz')",
+              :class="{'load-on': !state['pw']}")
+              .fa.fa-bullseye.ico
+              span.lbl Probe XYZ
+            button.jbtn(@click="showProbeDialog('z')",
+              :class="{'load-on': !state['pw']}")
+              .fa.fa-bullseye.ico
+              span.lbl Probe Z
 
-              td(style="height:100px", align="center", colspan="2")
-                button(:class="state['pw'] ? '' : 'load-on'",
-                  style="height:100px;width:200px",
-                  @click="showProbeDialog('z')")
-                  | Probe Z
+          // Row 4 — A axis (rotary) when no W and rotary is enabled
+          // (Vue 1 has no v-else-if; we negate w.enabled explicitly.)
+          template(v-if="!w.enabled && state['2an'] == 3")
+            button.jbtn.dir(@click="jog_fn(0, 0, 0, -1)")
+              .fa.fa-rotate-left.ico
+              span.lbl A−
+            button.jbtn.ghost(@click="showMoveToZeroDialog('a')")
+              span.lbl A
+              span Origin
+            button.jbtn.dir(@click="jog_fn(0, 0, 0, 1)")
+              .fa.fa-rotate-right.ico
+              span.lbl A+
+            button.jbtn(@click="show_probe_dialog=true",
+              :class="{'load-on': !state['pw']}")
+              .fa.fa-bullseye.ico
+              span.lbl Probe
 
-        td(style="vertical-align: top;")
-          table.axes
-            tr(:class="axes.klass")
-              th.name Axis
-              th.position Position
-              th.absolute Absolute
-              th.offset Offset
-              th.state State
-              th.tstate Toolpath
-              th.actions
-                button.pure-button(disabled, style="height:60px;width:60px;display:none;")
+          // Row 4 — fallback probe / zero / home shortcuts
+          template(v-if="!w.enabled && state['2an'] != 3")
+            button.jbtn(@click="showProbeDialog('xyz')",
+              :class="{'load-on': !state['pw']}")
+              .fa.fa-bullseye.ico
+              span.lbl Probe XYZ
+            button.jbtn.ghost(@click="zero()", :disabled="!can_set_axis")
+              .fa.fa-location-dot.ico
+              span.lbl Zero all
+            button.jbtn(@click="showProbeDialog('z')",
+              :class="{'load-on': !state['pw']}")
+              .fa.fa-bullseye.ico
+              span.lbl Probe Z
+            button.jbtn.ghost(@click="home()")
+              .fa.fa-home.ico
+              span.lbl Home all
 
-                button.pure-button(:disabled="!can_set_axis",
-                  title="Zero all axis offsets.", @click="zero()",style="height:60px;width:60px")
-                  .fa.fa-map-marker
-
-                button.pure-button(title="Home all axes.", @click="home()",
-                  :disabled="!is_idle",style="height:60px;width:60px")
-                  .fa.fa-home
-            
-            each axis in 'xyzabc'
-              tr.axis(:class=`${axis}.klass`, v-if=`${axis}.enabled`,
-                :title=`${axis}.title`)
-                th.name= axis
-                td.position: unit-value(:value=`${axis}.pos`, precision=4)
-                td.absolute: unit-value(:value=`${axis}.abs`, precision=3)
-                td.offset: unit-value(:value=`${axis}.off`, precision=3)
-                td.state
-                  .fa(:class=`'fa-' + ${axis}.icon`)
-                  | {{#{axis}.state}}
-                td.tstate(:class=`${axis}.tklass`, :title=`${axis}.toolmsg`, @click=`showToolpathMessageDialog('${axis}')`)
-                  .fa(:class=`'fa-' + ${axis}.ticon`)
-                  | {{#{axis}.tstate}}
-
-                th.actions
-                  button.pure-button(:disabled="!can_set_axis",
-                    title=`Set {{'${axis}' | upper}} axis position.`,
-                    @click=`show_set_position('${axis}')`, style="height:60px;width:60px")
-                    .fa.fa-cog
-
-                  button.pure-button(:disabled="!can_set_axis",
-                    title=`Zero {{'${axis}' | upper}} axis offset.`,
-                   @click=`zero('${axis}')`, style="height:60px;width:60px")
-                    .fa.fa-map-marker
-
-                  button.pure-button(:disabled="!is_idle", @click=`home('${axis}')`,
-                    title=`Home {{'${axis}' | upper}} axis.`, style="height:60px;width:60px")
-                    .fa.fa-home
-      
-      tr(style="vertical-align: top;")
-        td
-          table(width="100%")
-            tr
-              td(style="text-align:center")
-                table.info
-                  tr
-                    th State
-                    td(:class="{attention: highlight_state}") {{mach_state}}
-
-                  tr
-                    th Message
-                    td.message(:class="{attention: highlight_state}")
-                      | {{message.replace(/^#/, '')}}
-
-                  tr
-                    th Display Units
-                    td.units
-                      select(v-model="display_units")
-                        option(value="METRIC") METRIC
-                        option(value="IMPERIAL") IMPERIAL
-
-                  tr(title="Active tool")
-                    th Tool
-                    td {{state.tool || 0}}
-
-              td
-                table.info
-                  tr(
-                    title="Current velocity in {{metric ? 'meters' : 'inches'}} per minute")
-                    th Velocity
-                    td
-                      unit-value(:value="state.v", precision="2", unit="", iunit="",
-                        scale="0.0254")
-                      | {{metric ? ' m/min' : ' IPM'}}
-
-                  tr(title="Programmed feed rate.")
-                    th Feed
-                    td
-                      unit-value(:value="state.feed", precision="2", unit="", iunit="")
-                      | {{metric ? ' mm/min' : ' IPM'}}
-
-                  tr(title="Programed and actual speed.")
-                    th Speed
-                    td
-                      | {{state.speed || 0 | fixed 0}}
-                      span(v-if="!isNaN(state.s)")  ({{state.s | fixed 0}})
-                      = ' RPM'
-
-                  tr(title="Load switch states.")
-                    th Loads
-                    td
-                      span(:class="state['1oa'] ? 'load-on' : ''")
-                        | 1:{{state['1oa'] ? 'On' : 'Off'}}
-                      |  
-                      span(:class="state['2oa'] ? 'load-on' : ''")
-                        | 2:{{state['2oa'] ? 'On' : 'Off'}}
-
-              td
-                table.info
-                  tr
-                    th Remaining
-                    td(title="Total run time (days:hours:mins:secs)").
-                      #[span(v-if="plan_time_remaining") {{plan_time_remaining | time}} of]
-                      {{toolpath.time | time}}
-
-                  tr
-                    th ETA
-                    td.eta {{eta}}
-
-                  tr
-                    th Line
-                    td
-                      | {{0 <= state.line ? state.line : 0 | number}}
-                      span(v-if="toolpath.lines")
-                        | &nbsp;of {{toolpath.lines | number}}
-
-                  tr
-                    th Progress
-                    td.progress
-                      label {{(progress || 0) | percent}}
-                      .bar(:style="'width:' + (progress || 0) * 100 + '%'")
-
-    .macros-div(class="present")
-       button.macros-button(title="Click to run Macros",v-for="(index,macros) in state.macros",
-          @click="run_macro(index)",:disabled="!is_ready",v-bind:style="{ backgroundColor: macros.color }") {{macros.name}}
-
-    .tabs
-     
-      input#tab1(type="radio", name="tabs",checked="" @click="tab = 'auto'")
-      label(for="tab1", title="Run GCode programs",style="height:50px;width:100px") Auto
-
-      input#tab2(type="radio", name="tabs", @click="tab = 'mdi'")
-      label(for="tab2", title="Manual GCode entry",style="height:50px;width:100px") MDI
-
-      input#tab3(type="radio", name="tabs", @click="tab = 'messages'")
-      label(for="tab3",style="height:50px;width:100px") Messages
-
-      input#tab4(type="radio", name="tabs", @click="tab = 'indicators'")
-      label(for="tab4",style="height:50px;width:100px") Indicators
-
-
-
-      
-      section#content1.tab-content.pure-form
-        .toolbar.pure-control-group
-          button.pure-button(:class="{'attention': is_holding}",
-            title="{{is_running ? 'Pause' : 'Start'}} program.",
-            @click="start_pause", :disabled="!state.selected",
-            style="height:100px;width:100px;font-weight:normal")
-            img(v-if="is_running" src="images/pause_gcode.png" style="height: 55px;")
-            img(v-else src="images/play_gcode.png" style="height: 55px;")
-
-          button.pure-button(title="Stop program.", @click="stop", style="height:100px;width:100px;font-weight:normal")
-            img(src="images/stop.png" style="height: 55px;")
-
-          button.pure-button(title="Pause program at next optional stop (M1).",
-            @click="optional_pause", v-if="false", style="height:100px;width:100px;font-weight:normal")
-            .fa.fa-stop-circle-o
-
-          message(:show.sync="uploading_files")
-            h3(slot="header") Files uploading
-            div(slot="body") 
-              h3 Please wait...
-              p  
-              p The files are currently being uploaded.
-              p Do not close the window.
-            div(slot="footer")
-
-          button.pure-button(title="Execute one program step.", @click="step",
-            :disabled="(!is_ready && !is_holding) || !state.selected",
-            v-if="false", style="height:100px;width:100px;font-weight:normal")
-            .fa.fa-step-forward
-          
-          button.pure-button(title="Upload a new GCode folder.", @click="open_folder",
-            :disabled="!is_ready",style="height:100px;width:100px;font-weight:normal")
-            img(src="images/upload_folder.png" style="height: 65px;")
-
-          form.gcode-folder-input.file-upload
-            input#folderInput(type="file", @change="upload_folder", :disabled="!is_ready",
-              webkitdirectory, directory)
-          
-          button.pure-button(title="Upload a new GCode program.", @click="open_file",
-            :disabled="!is_ready",style="height:100px;width:100px;font-weight:normal")
-            img(src="images/upload_gcode.png" style="height: 65px;")
-
-          form.gcode-file-input.file-upload
-            input(type="file", @change="upload_file", :disabled="!is_ready",
-              accept=".nc,.ngc,.gcode,.gc", multiple)
-
-          a(:disabled="!state.selected", download,
-              :href="'/api/file/' + state.selected",
-              title="Download the selected GCode program.")
-            button.pure-button(:disabled="!state.selected", style="height:100px;width:100px")
-              img(src="images/download_gcode.png" style="height: 65px;")
-
-          button.pure-button(title="Delete current GCode program.",
-            @click="deleteGCode = true",
-            :disabled="!state.selected || !is_ready",style="height:100px;width:100px;font-weight:normal")
-            img(src="images/delete_gcode.png" style="height: 55px;")
-
-          message.error-message(:show.sync="deleteGCode")
-            h3(slot="header") Select files to delete:
-            div(slot="body")
-              input.search-bar(type="text", v-model="search_query", placeholder="Search Files...")
-              .container
-                .folders
-                  h3 Folders
-                  div(v-for="(index, folder) in state.gcode_list", :key="index", @click="populateFiles(index)",
-                    class="folder-item", :class="{ selected: index === selected_folder_index }") {{ folder.name }}
-                .files
-                  h3 Files
-                  label.file-item(v-for="item in gcode_filtered_files" :key="item")
-                    input(type="checkbox" :value="item" v-model="selected_items_to_delete")
-                    |  {{ item }}
-            div(slot="footer")
-              button.pure-button(@click="cancel_delete",style="height:50px") Cancel
-              //- button.pure-button.button-error(@click="delete_all_except_macros")
-              //-   .fa.fa-trash
-              //-   | &nbsp;All
-              button.pure-button.button-success(@click="delete_current",style="height:50px")
-                .fa.fa-trash
-                | &nbsp;Selected
-
-          .drop-down-container
-            message(:show.sync="create_folder")
-              h3(slot="header") Enter folder name:
-              div(slot="body")
-                input.input-name(type="text",minlength='1',maxlength='15',style ="margin-top:1rem;margin-bottom:2rem;",
-                  id="folder-name" ,v-model="folder_name",@keypress="edited_folder_name")
-
-              div(slot="footer")
-                button.pure-button(@click="cancel_new_folder") Cancel
-                button.pure-button.button-success(@click="create_new_folder",:disabled="!edited")
-                  | Create
-
-            message(:show.sync="confirmDelete")
-              h3(slot="header") Delete Folder?
-              div(slot="body")
-                  p Are you sure to delete the folder?
-                  
-              div(slot="footer")
-                button.pure-button(@click="confirmDelete=false") Cancel
-                button.pure-button.button-error(@click="delete_folder") Folder only
-                button.pure-button.button-success(@click="delete_folder_and_files") Folder and files 
-            
-            button.pure-button(title="Create a new folder.", @click="create_folder=true",
-              :disabled="!is_ready",style="height:100%")
-              | Create Folder
-            
-            button.pure-button(title="Delete a folder.", @click="confirmDelete=true",
-              :disabled="!is_ready",style="height:100%;margin-left:5px")
-              | Delete Folder
-
-            select(title="Select previously uploaded GCode folder.",
-              v-model="state.folder", @change="reset_gcode", :disabled="!is_ready",
-              style="max-width:100%;margin-left:5px")
-              option( selected='' value='default')  Default folder
-              option(v-for="file in gcode_folders", :value="file") {{file}}
-
-            select(title="Select previously uploaded GCode programs.",
-              v-model="state.selected", @change="load", :disabled="!is_ready",
-              style="max-width:300px;margin-left:5px")
-              option(v-for="file in gcode_files", :value="file") {{file}}
-            
-            button.pure-button(@click="toggle_sorting", :disabled="!is_ready",
-              style="height:75%")
-              | {{files_sortby}}
-
-          .progress(v-if="toolpath_progress && toolpath_progress < 1",
-            title="Simulating GCode to check for errors, calculate ETA and " +
-              "generate 3D view.  You can run GCode before the simulation " +
-              "finishes.")
-            div(:style="'width:' + (toolpath_progress || 0) * 100 + '%'")
-              label Simulating {{(toolpath_progress || 0) | percent}}
-
-        path-viewer(:toolpath="toolpath", :state="state", :config="config")
-        gcode-viewer
-
-      section#content2.tab-content
-        .mdi.pure-form(title="Manual GCode entry.")
-          button.pure-button(:disabled="!can_mdi",
-            :class="{'attention': is_holding}",
-            title="{{is_running ? 'Pause' : 'Start'}} command.",
-            @click="mdi_start_pause",style="height:100px;width:100px")
-            .fa(:class="is_running ? 'fa-pause' : 'fa-play'")
-
-          button.pure-button(title="Stop command.", @click="stop",style="height:100px;width:100px")
+      // ===== NOW RUNNING (replaces jog grid only while a G-code
+      // program is actually executing). Jogging is excluded.
+      .running-panel(v-if="is_program_executing")
+        .running-top
+          div
+            .running-file
+              .fa.fa-file-code
+              span(v-if="state.selected") &nbsp;{{state.selected}}
+              span(v-else) &nbsp;{{(mach_state || 'BUSY').toLowerCase()}}
+            .running-meta
+              span(v-if="is_running") {{ (mach_state || 'RUNNING').toLowerCase() }}
+              span(v-if="is_holding") paused
+              span(v-if="is_holding && pause_reason")  · {{pause_reason}}
+              span(v-if="is_stopping") stopping
+              span(v-if="toolpath.lines")  · line {{state.line || 0 | number}} / {{toolpath.lines | number}}
+              span(v-if="plan_time_remaining")  · ETA {{plan_time_remaining | time}}
+          .running-pct
+            | {{((progress || 0) * 100) | fixed 0}}
+            span %
+        .running-progress
+          div(:style="'width:' + ((progress || 0) * 100) + '%'")
+        .running-stats
+          .running-stat
+            .lbl Velocity
+            .val
+              unit-value(:value="state.v", precision="2", unit="", iunit="", scale="0.0254")
+              | &nbsp;{{metric ? 'm/min' : 'IPM'}}
+          .running-stat
+            .lbl Feed
+            .val
+              unit-value(:value="state.feed", precision="0", unit="", iunit="")
+              | &nbsp;{{metric ? 'mm/min' : 'IPM'}}
+          .running-stat
+            .lbl Spindle
+            .val
+              | {{(state.speed || 0) | fixed 0}}
+              span(v-if="state.s != null && !isNaN(state.s)")  ({{state.s | fixed 0}})
+              | &nbsp;RPM
+          .running-stat
+            .lbl Tool
+            .val T{{state.tool || 0}}
+        .running-row
+          // While RUNNING the primary action is Pause; while HOLDING / STOPPING it's Resume.
+          button.tx-btn.pause(v-if="is_running", @click="pause()")
+            .fa.fa-pause
+            span.lbl PAUSE
+          button.tx-btn.run(v-if="is_holding || is_stopping", @click="unpause()")
+            .fa.fa-play
+            span.lbl RESUME
+          button.tx-btn.stop(@click="stop()")
             .fa.fa-stop
+            span.lbl STOP
+          button.tx-btn.step(v-if="is_holding", @click="step()")
+            .fa.fa-forward-step
+            span.lbl STEP
 
-          input(v-model="mdi", :disabled="!can_mdi", @keyup.enter="submit_mdi")
+      // ===== DRO + status strip =====
+      .right-col
 
-        div
-          em The machine is currently operating in #[strong {{mach_units}}] units.  Use G20/G21 to switch units.
+        .dro-card
+          .dro-head
+            div Axis
+            div Position
+            div Absolute
+            div Offset
+            .actions-cell
+              // Master Home All. Each row's Actions cell has a per-axis
+              // home button; this header-level button homes every
+              // enabled axis (legacy Onefinity behavior). Auto-includes
+              // the auxiliary A axis when it is enabled.
+              button.icon-btn(:disabled="!is_idle",
+                title="Home all axes.", @click="home_all()")
+                .fa.fa-house-chimney
 
-        .history(:class="{placeholder: !history}")
-          span(v-if="!history.length") MDI history displays here.
-          ul
-            li(v-for="item in history", @click="load_history($index)",
-               track-by="$index")
-              | {{item}}
+          // Per-axis rows — keep unit-value + bindings from axis-vars
+          each axis in 'xyzabc'
+            .dro-row(:class=`${axis}.klass + ' ' + ${axis}.tklass`,
+              v-if=`${axis}.enabled`,
+              :title=`${axis}.toolmsg ? (${axis}.title + ' — ' + ${axis}.toolmsg) : ${axis}.title`)
+              .dro-axis(:class=`'axis-' + '${axis}'`)= axis.toUpperCase()
+              .dro-pos: unit-value(:value=`${axis}.pos`, precision=4)
+              .dro-sec: unit-value(:value=`${axis}.abs`, precision=3)
+              .dro-sec: unit-value(:value=`${axis}.off`, precision=3)
+              .actions-cell
+                button.icon-btn(:disabled="!can_set_axis",
+                  :title=`'Set ${axis.toUpperCase()} axis position.'`,
+                  @click=`show_set_position('${axis}')`)
+                  .fa.fa-gear
+                button.icon-btn(:class=`${axis}.tklass.indexOf('error') !== -1 ? 'state-red' : (${axis}.tklass.indexOf('warn') !== -1 ? 'state-amber' : 'state-green')`,
+                  :disabled="!can_set_axis",
+                  :title=`${axis}.toolmsg || ('Zero ${axis.toUpperCase()} axis offset.')`,
+                  @click=`zero('${axis}')`)
+                  .fa.fa-location-dot
+                button.icon-btn(:class=`${axis}.klass.indexOf('error') !== -1 ? 'state-red' : (${axis}.homed ? 'state-green' : 'state-amber')`,
+                  :disabled="!is_idle",
+                  :title=`${axis}.title`,
+                  @click=`home('${axis}')`)
+                  .fa.fa-home
 
-      section#content3.tab-content
-        console
+          // Legacy auxiliary-axis row - shown only when the auxcnc stepper is
+          // *not* exposed as a virtual A axis. After v2 the standard
+          // A row above renders this axis natively (with full offset
+          // + set-position support); this row only appears on legacy
+          // installs that haven't migrated yet.
+          .dro-row(:class="w.klass + ' ' + w.tklass",
+            v-if="w.enabled && !a.enabled",
+            :title="w.title")
+            .dro-axis.axis-w W
+            .dro-pos: unit-value(:value="w.pos", precision=4)
+            .dro-sec: unit-value(:value="w.abs", precision=3)
+            .dro-sec —
+            .actions-cell
+              button.icon-btn(disabled, style="visibility:hidden")
+                .fa.fa-gear
+              button.icon-btn(disabled, style="visibility:hidden")
+                .fa.fa-location-dot
+              button.icon-btn(:class="w.homed ? 'state-green' : 'state-amber'",
+                :disabled="!w.enabled",
+                title="Home auxiliary axis.", @click="aux_home()")
+                .fa.fa-home
 
-      section#content4.tab-content
-        indicators(:state="state", :template="template")
+        // ----- Status strip -----
+        .status-strip
+          .stat-card
+            .stat-label State
+            .stat-val(:class="state_kpi_class") {{mach_state || '--'}}
+            .stat-sub(v-if="message") {{message.replace(/^#/, '')}}
+            .stat-sub(v-else) No alerts
 
-    .override(title="Feed rate override.")
-      label Feed
-      input(type="range", min="0", max="2", step="0.01",
-        v-model="feed_override", @change="override_feed")
-      span.percent {{feed_override | percent 0}}
+          .stat-card
+            .stat-label Velocity / Feed
+            .stat-val
+              unit-value(:value="state.v", precision="2", unit="", iunit="",
+                scale="0.0254")
+              |  ·&nbsp;
+              unit-value(:value="state.feed", precision="0", unit="", iunit="")
+            .stat-sub {{metric ? 'm/min · mm/min' : 'IPM · IPM'}}
 
-    .override(title="Spindle speed override.")
-      label Speed
-      input(type="range", min="0", max="2", step="0.01",
-        v-model="speed_override", @change="override_speed")
-      span.percent {{speed_override | percent 0}}
+          .stat-card.stat-tappable(@click="overrides_open = !overrides_open",
+            :class="{open: overrides_open}", title="Tap to adjust feed/spindle override")
+            .stat-label Spindle
+            .stat-val
+              | {{(state.speed || 0) | fixed 0}}
+              span(v-if="state.s != null && !isNaN(state.s)")  ({{state.s | fixed 0}})
+            .stat-sub
+              | RPM (commanded / actual)
+              .fa.fa-sliders.tap-hint(title="Open override drawer")
 
-    
+          .stat-card
+            .stat-label Job
+            .stat-val
+              | {{0 <= state.line ? state.line : 0 | number}}
+              span(v-if="toolpath.lines")
+                |  / {{toolpath.lines | number}}
+            .stat-sub(v-if="plan_time_remaining || toolpath.time")
+              | Line · {{plan_time_remaining ? (plan_time_remaining | time) : (toolpath.time | time)}} remaining
+            .stat-sub(v-else) Line · ETA --
+
+    // ----- Macro row (slice 0..7); full list lives in Settings → Macros -----
+    // The colored left stripe (.has-color) is suppressed for white,
+    // near-white and other default placeholder colors so unconfigured
+    // macros render as clean slate tiles instead of looking lopsided.
+    .macro-row(v-if="state.macros && state.macros.length")
+      button.macro-btn(v-for="(index, macros) in state.macros.slice(0, 8)",
+        title="Click to run macro",
+        @click="run_macro(index)",
+        :disabled="!is_ready",
+        :class="{'has-color': has_macro_color(macros)}",
+        :style="has_macro_color(macros) ? {borderLeftColor: macros.color} : {}")
+        span.mnum {{index + 1}}
+        span.mname {{macros.name || ('Macro ' + (index + 1))}}
+
+    // ----- Override drawer (anchored to bottom; toggled by Spindle KPI tile) -----
+    .override-drawer(:class="{open: overrides_open}")
+      .od-head
+        .od-title
+          .fa.fa-sliders
+          | &nbsp;Overrides
+        button.od-close(@click="overrides_open = false") ✕
+      .od-body
+        .od-row
+          label Feed
+          input(type="range", min="0", max="2", step="0.01",
+            v-model="feed_override", @change="override_feed")
+          .od-val {{feed_override | percent 0}}
+          button.od-reset(@click="feed_override = 1; override_feed()") Reset 100%
+        .od-row
+          label Spindle
+          input(type="range", min="0", max="2", step="0.01",
+            v-model="speed_override", @change="override_speed")
+          .od-val {{speed_override | percent 0}}
+          button.od-reset(@click="speed_override = 1; override_speed()") Reset 100%

src/pug/templates/estop.pug

@@ -2,6 +2,8 @@ script#estop-template(type="text/x-template")
   svg(version="1.1", xmlns:svg="http://www.w3.org/2000/svg",
     xmlns="http://www.w3.org/2000/svg",
     xmlns:xlink="http://www.w3.org/1999/xlink",
+    viewBox="0 0 130 130",
+    preserveAspectRatio="xMidYMid meet",
     width="130", height="130")
       defs
         path#text-path-1(d="m 73.735,673.129 c 0,55.107 44.673,99.780 99.780,99.780 55.107,0 99.780,-44.673 99.780,-99.780 0,-55.107 -44.673,-99.780 -99.780,-99.780 -55.107,0 -99.780,44.673 -99.780,99.780 z")

src/pug/templates/indicators.pug

@@ -6,11 +6,11 @@ script#indicators-template(type="text/x-template")
 
       tr
         td
-         .fa.fa-plus-circle.io
+         .fa.fa-circle-plus.io
         th Hi/+3.3v
         th.separator
         td
-         .fa.fa-minus-circle.io
+         .fa.fa-circle-minus.io
         th Lo/Gnd
         th.separator
         td
@@ -22,7 +22,7 @@ script#indicators-template(type="text/x-template")
         th Inactive
         th.separator
         td
-         .fa.fa-circle-o.io
+         .far.fa-circle.io
         th Tristated/Disabled
 
     table.inputs
@@ -169,14 +169,14 @@ script#indicators-template(type="text/x-template")
 
       tr
         th Motor
-        th(title="Overtemperature fault"): .fa.fa-thermometer-full
+        th(title="Overtemperature fault"): .fa.fa-temperature-full
         th(title="Overcurrent motor channel A") A #[.fa.fa-bolt]
         th(title="Predriver fault motor channel A")
-          | A #[.fa.fa-exclamation-triangle]
+          | A #[.fa.fa-triangle-exclamation]
         th(title="Overcurrent motor channel B") B #[.fa.fa-bolt]
         th(title="Predriver fault motor channel B")
-          | B #[.fa.fa-exclamation-triangle]
-        th(title="Driver communication failure"): .fa.fa-handshake-o
+          | B #[.fa.fa-triangle-exclamation]
+        th(title="Driver communication failure"): .fa.fa-handshake
         th(title="Reset all motor flags")
           .fa.fa-eraser(@click="motor_reset()")
 

src/pug/templates/path-viewer.pug

@@ -3,7 +3,7 @@ script#path-viewer-template(type="text/x-template")
     .path-viewer-toolbar
       .tool-button(title="Toggle path view size.",
         @click="small = !small", :class="{active: !small}")
-        .fa.fa-arrows-alt
+        .fa.fa-up-down-left-right
 
       .tool-button(@click="showTool = !showTool", :class="{active: showTool}",
         title="Show/hide tool.")

src/pug/templates/program-view.pug

@@ -0,0 +1,142 @@
+script#program-view-template(type="text/x-template")
+  .program-page
+
+    // ----- Modal dialogs -----
+    message(:show.sync="showGcodeMessage")
+      h3(slot="header") Processing New File
+      div(slot="body")
+        h3 Please wait..
+        p Simulating GCode to check for errors, calculate ETA and generate 3D view.
+      div(slot="footer")
+        label Simulating {{(toolpath_progress || 0) | percent}}
+
+    message(:show.sync="GCodeNotFound")
+      h3(slot="header") File not found
+      div(slot="body")
+        p It seems like the file you selected cannot be found. Try uploading again.
+      div(slot="footer")
+        button.pure-button.button-error(@click="GCodeNotFound=false") OK
+
+    message(:show.sync="uploading_files")
+      h3(slot="header") Files uploading
+      div(slot="body")
+        h3 Please wait...
+        p
+        p The files are currently being uploaded.
+        p Do not close the window.
+      div(slot="footer")
+
+    message.error-message(:show.sync="deleteGCode")
+      h3(slot="header") Select files to delete:
+      div(slot="body")
+        input.search-bar(type="text", v-model="search_query", placeholder="Search Files...")
+        .container
+          .folders
+            h3 Folders
+            div(v-for="(index, folder) in state.gcode_list", :key="index",
+              @click="populateFiles(index)",
+              class="folder-item",
+              :class="{ selected: index === selected_folder_index }") {{ folder.name }}
+          .files
+            h3 Files
+            label.file-item(v-for="item in gcode_filtered_files", :key="item")
+              input(type="checkbox", :value="item", v-model="selected_items_to_delete")
+              |  {{ item }}
+      div(slot="footer")
+        button.pure-button(@click="cancel_delete", style="height:50px") Cancel
+        button.pure-button.button-success(@click="delete_current", style="height:50px")
+          .fa.fa-trash
+          |  Selected
+
+    message(:show.sync="create_folder")
+      h3(slot="header") Enter folder name:
+      div(slot="body")
+        input.input-name(type="text", minlength="1", maxlength="15",
+          style="margin-top:1rem;margin-bottom:2rem;",
+          id="folder-name", v-model="folder_name", @keypress="edited_folder_name")
+      div(slot="footer")
+        button.pure-button(@click="cancel_new_folder") Cancel
+        button.pure-button.button-success(@click="create_new_folder", :disabled="!edited") Create
+
+    message(:show.sync="confirmDelete")
+      h3(slot="header") Delete Folder?
+      div(slot="body")
+        p Are you sure to delete the folder?
+      div(slot="footer")
+        button.pure-button(@click="confirmDelete=false") Cancel
+        button.pure-button.button-error(@click="delete_folder") Folder only
+        button.pure-button.button-success(@click="delete_folder_and_files") Folder and files
+
+    .program-card
+
+      // Action bar (RUN / STOP / Upload / Download / Delete)
+      .action-bar
+        button.action-btn.run(:class="{'attention': is_holding}",
+          @click="start_pause", :disabled="!state.selected",
+          :title="is_running ? 'Pause program.' : 'Start program.'")
+          .fa.fa-play.ico(v-if="!is_running")
+          .fa.fa-pause.ico(v-else)
+          span {{is_running ? 'PAUSE' : 'RUN'}}
+        button.action-btn.stop(@click="stop", title="Stop program.")
+          .fa.fa-stop.ico
+          span STOP
+        button.action-btn(@click="open_folder", :disabled="!is_ready",
+          title="Upload a new GCode folder.")
+          .fa.fa-folder-plus.ico
+          span UPLOAD FOLDER
+        form.gcode-folder-input.file-upload
+          input#folderInput(type="file", @change="upload_folder",
+            :disabled="!is_ready", webkitdirectory, directory)
+        button.action-btn(@click="open_file", :disabled="!is_ready",
+          title="Upload a new GCode program.")
+          .fa.fa-file-arrow-up.ico
+          span UPLOAD FILE
+        form.gcode-file-input.file-upload
+          input(type="file", @change="upload_file", :disabled="!is_ready",
+            accept=".nc,.ngc,.gcode,.gc", multiple)
+        a(:href="state.selected ? '/api/file/' + state.selected : '#'",
+          download, :class="{disabled: !state.selected}",
+          title="Download the selected GCode program.")
+          button.action-btn(:disabled="!state.selected")
+            .fa.fa-file-arrow-down.ico
+            span DOWNLOAD FILE
+        button.action-btn.danger(@click="deleteGCode = true",
+          :disabled="!state.selected || !is_ready",
+          title="Delete current GCode program.")
+          .fa.fa-trash.ico
+          span DELETE
+
+      // File / folder selectors
+      .file-bar
+        button.file-btn(@click="create_folder=true", :disabled="!is_ready")
+          .fa.fa-folder-plus
+          |  Create Folder
+        button.file-btn(@click="confirmDelete=true", :disabled="!is_ready")
+          .fa.fa-folder-minus
+          |  Delete Folder
+        select.file-select(title="Select previously uploaded GCode folder.",
+          v-model="state.folder", @change="reset_gcode", :disabled="!is_ready")
+          option(selected, value="default") Default folder
+          option(v-for="file in gcode_folders", :value="file") {{file}}
+        select.file-select.primary(title="Select previously uploaded GCode programs.",
+          v-model="state.selected", @change="load", :disabled="!is_ready")
+          option(value="") (no file)
+          option(v-for="file in gcode_files", :value="file") {{file}}
+        button.file-btn(@click="toggle_sorting", :disabled="!is_ready")
+          .fa.fa-arrow-down-wide-short
+          |  {{files_sortby}}
+
+      // Body: gcode listing on the left, 3D viewer on the right.
+      // The 3D path-viewer is suppressed when the UI is loaded by
+      // the Pi's onboard kiosk browser — the VideoCore IV cannot
+      // run three.js at a usable frame rate. Off-Pi clients still
+      // see the full split.
+      .program-body(:class="{'no-preview': is_kiosk}")
+        gcode-viewer
+        path-viewer(v-if="!is_kiosk", :toolpath="toolpath",
+          :state="state", :config="config")
+
+      .progress-bar(v-if="toolpath_progress && toolpath_progress < 1",
+        title="Simulating GCode to check for errors, calculate ETA and generate 3D view.")
+        div(:style="'width:' + (toolpath_progress || 0) * 100 + '%'")
+          label Simulating {{(toolpath_progress || 0) | percent}}

src/pug/templates/settings-shell.pug

@@ -0,0 +1,58 @@
+script#settings-shell-view-template(type="text/x-template")
+  .settings-shell
+    aside.settings-rail
+      // Use a single v-for over a data-driven items array so every
+      // rail item shares the same compiled :class binding template.
+      // This sidesteps a Vue 1 quirk where sibling-with-different-
+      // expression :class bindings sometimes fail to re-evaluate on
+      // hash navigation, leaving stale `.active` classes.
+      template(v-for="item in rail_items")
+        .set-section(v-if="item.section") {{item.section}}
+        a.set-item(v-if="!item.section", :class="{active: is_active(item)}",
+          :href="item.href", @click="on_rail_click(item, $event)")
+          .fa(:class="item.icon")
+          |  {{item.label}}
+      .set-rail-foot
+        button.sp-shutdown(@click="showShutdownDialog")
+          .fa.fa-power-off
+          |  Shutdown
+        button.sp-save(:disabled="!$root.modified", @click="$root.save()")
+          .fa.fa-save
+          |  Save{{$root.modified ? '*' : ''}}
+
+    .settings-content
+      // Explicit v-if cascade so the inner template swaps reactively
+      // when sub changes (Vue 1's `<component :is>` does not always
+      // re-evaluate dynamic strings inside a kept-alive parent).
+      // The Svelte settings views read many config keys eagerly on
+      // attach (settings.units, settings.easy-adapter, motion.*),
+      // so we gate the inner mount on config_ready.
+      settings-view-inner(v-if="sub === 'settings' && config_ready",
+        section="display",
+        :index="index", :config="config", :template="template", :state="state")
+      settings-view-inner(v-if="sub === 'probing' && config_ready",
+        section="probing",
+        :index="index", :config="config", :template="template", :state="state")
+      settings-view-inner(v-if="sub === 'gcode' && config_ready",
+        section="gcode",
+        :index="index", :config="config", :template="template", :state="state")
+      admin-general-view(v-if="sub === 'admin-general' && config_ready",
+        :index="index", :config="config", :template="template", :state="state")
+      admin-network-view(v-if="sub === 'admin-network' && config_ready",
+        :index="index", :config="config", :template="template", :state="state")
+      motor-view(v-if="sub === 'motor' && config_ready",
+        :index="index", :config="config", :template="template", :state="state")
+      tool-view(v-if="sub === 'tool' && config_ready",
+        :index="index", :config="config", :template="template", :state="state")
+      io-view(v-if="sub === 'io' && config_ready",
+        :index="index", :config="config", :template="template", :state="state")
+      a-axis-view(v-if="sub === 'a-axis' && config_ready",
+        :index="index", :config="config", :template="template", :state="state")
+      macros-view(v-if="sub === 'macros' && config_ready",
+        :index="index", :config="config", :template="template", :state="state")
+      help-view(v-if="sub === 'help' && config_ready",
+        :index="index", :config="config", :template="template", :state="state")
+      cheat-sheet-view(v-if="sub === 'cheat-sheet' && config_ready",
+        :index="index", :config="config", :template="template", :state="state")
+      .settings-loading(v-if="!config_ready")
+        | Loading configuration…

src/pug/templates/tool-view.pug

@@ -433,4 +433,4 @@ script#tool-view-template(type="text/x-template")
           | Other settings according to the
           |
           a(href="https://buildbotics.com/upload/vfd/stepperonline-v70.pdf",
-            target="_blank") Stepper Online V70 VFD manual
+            target="_blank") Stepper Online V70 VFD manual

src/py/bbctrl/AuxAxis.py

@@ -0,0 +1,706 @@
+################################################################################
+#
+# AuxAxis - W-axis serial driver for the auxcnc ESP32 controller
+#
+# Owns /dev/ttyUSB0 (or whatever serial.port is configured to). Provides
+# blocking RPCs for use from a hook thread. Maintains:
+#
+#   - aux_present : True if serial is open and we've seen a boot banner
+#   - aux_homed   : True if we've successfully run HOME since last reset
+#   - aux_pos     : current logical position in mm (from ESP step counter
+#                   * (1 / steps_per_mm * dir_sign))
+#
+# Real-time decisions (limit switch monitoring, step pulse generation) live
+# on the ESP. The host is responsible for units, soft limits, and tracking
+# whether we've ever boot-cycled the ESP since last home.
+#
+################################################################################
+
+import os
+import json
+import time
+import threading
+import traceback
+
+try:
+    import serial
+except ImportError:
+    serial = None
+
+
+# Default config; overridden by ./aux.json or ctrl.config.
+DEFAULTS = {
+    'enabled':           False,
+    'port':              '/dev/ttyUSB0',
+    'baud':              115200,
+    'steps_per_mm':      80.0,    # logical steps per mm of axis travel
+    'dir_sign':          1,       # +1 or -1: maps logical+ to motor+ steps
+    # Logical axis letter exposed to gplan. The auxcnc ESP stepper
+    # is presented to the planner as this axis (default 'a' = standard
+    # 4th axis). gcode uses A for moves; the host ExternalAxis layer
+    # forks A motion to the ESP transparently.
+    'axis_letter':       'a',
+    'min_mm':            0.0,     # soft limit min (mm), exposed as 4tn
+    'max_mm':            100.0,   # soft limit max (mm), exposed as 4tm
+    # Per-axis kinematic limits used to populate the planner's config.
+    # Units match the bbctrl/onefinity per-motor convention so the
+    # values are directly comparable to motors 0-3:
+    #   max_velocity_m_per_min   m/min   (planner sees * 1000 = mm/min)
+    #   max_accel_km_per_min2    km/min2 (planner sees * 1e6 = mm/min2)
+    #   max_jerk_km_per_min3     km/min3 (planner sees * 1e6 = mm/min3)
+    'max_velocity_m_per_min':   6.0,
+    'max_accel_km_per_min2':  100.0,
+    'max_jerk_km_per_min3':   500.0,
+    # Informational only - rate caps that actually clamp the move
+    # are on the ESP via step_max_sps below.
+    'max_feed_mm_min':   600.0,
+    'home_dir':          '-',     # which direction is "toward limit" (host's view)
+    'home_position_mm':  0.0,     # mm value to assign at home
+    # ESP-side homing rates (steps/sec). Pushed via HOMECFG on connect.
+    # Speeds tuned for a typical 25 steps/mm aux drive (so 1 step =
+    # 0.04 mm). With the limit-aware ESP firmware these values give
+    # a brisk seek (100 mm/s), enough backoff to clear the switch
+    # hysteresis (16 mm), and a slow re-engage (10 mm/s) that's
+    # accurate without being painfully slow on a longer axis.
+    'home_fast_sps':     2500,    # ≈ 100 mm/s @ 25 steps/mm
+    'home_slow_sps':     250,     # ≈  10 mm/s
+    'home_backoff_steps': 400,    # ≈  16 mm
+    'home_maxtravel_steps': 200000,
+    # If HOME starts with the limit switch already tripped the ESP
+    # first moves this many steps away from the limit and then
+    # rechecks. If the switch is still active afterward, HOME hard-
+    # fails (refuses to set zero blindly when we may already be past
+    # the home position). Default ≈ 10 mm @ 25 steps/mm. Set to 0 to
+    # disable the preclear move (HOME then fails immediately if the
+    # switch reads active at start, matching the original behaviour).
+    'home_preclear_mm':  10.0,
+    'step_max_sps':      4000,    # ≈ 160 mm/s normal-move cap
+    'step_accel_sps2':   12000,
+    'step_start_sps':    200,
+    'limit_low':         True,
+    # ------------------------------------------------------------------
+    # Z-A coupling interlock
+    # ------------------------------------------------------------------
+    # The auxiliary A axis carries a tool that physically hangs below
+    # the Z-axis spindle nose. Beyond a certain Z descent the two
+    # collide unless A drops with Z. The constraint, in machine coords,
+    # is:
+    #     A_machine - Z_machine <= K
+    # where K = (A_home_mm - z_home_mm) + couple_z_clearance_mm.
+    # When enabled this is enforced everywhere motion can be
+    # initiated (planner, MDI, jog, file load) and the AuxPreprocessor
+    # injects pre-position A moves before Z descends past the safe
+    # band.
+    'couple_z_enabled':       True,
+    'couple_z_clearance_mm':  22.0,   # Z drop allowed before A must follow
+    'z_home_mm':              0.0,    # Z's machine position when homed
+}
+
+
+class AuxAxisError(Exception):
+    pass
+
+
+class AuxAxis(object):
+    def __init__(self, ctrl):
+        self.ctrl = ctrl
+        self.log = ctrl.log.get('AuxAxis')
+
+        self._cfg = dict(DEFAULTS)
+        self._load_config()
+
+        self._sp = None
+        self._sp_lock = threading.Lock()  # serial write/RPC serialization
+        self._rx_lock = threading.Lock()  # read-line buffer access
+        self._reader_thread = None
+        self._stop = threading.Event()
+
+        # Pending replies waiting for a [topic] line. Single-slot since we
+        # serialize RPCs via _sp_lock.
+        self._pending_topics = []
+        self._pending_replies = []
+        self._pending_cv = threading.Condition()
+
+        # Async lines that aren't replies (e.g. logs) are simply logged.
+        self._present = False
+        self._homed = False
+        self._pos_steps = 0  # ESP step counter mirror
+
+        # Publish initial state
+        self._publish_state()
+
+        if not self._cfg['enabled']:
+            self.log.info('Aux axis disabled in config')
+            return
+
+        if serial is None:
+            self.log.error('pyserial not available; aux axis disabled')
+            return
+
+        self._open()
+
+    # ------------------------------------------------------------------ config
+
+    def _config_path(self):
+        return self.ctrl.get_path(filename='aux.json')
+
+    # Legacy aux.json fields that have been renamed for clarity.
+    # Loaded values are migrated up on every load/save so existing
+    # installs keep working without operator intervention.
+    _LEGACY_FIELD_MAP = {
+        'min_w': 'min_mm',
+        'max_w': 'max_mm',
+    }
+
+    def _migrate_legacy_fields(self, cfg):
+        """In-place rename of legacy keys in `cfg` (dict). Returns
+        True if anything was migrated, so callers can decide whether
+        to persist the upgraded form.
+        """
+        migrated = False
+        for old, new in self._LEGACY_FIELD_MAP.items():
+            if old in cfg:
+                if new not in cfg:
+                    cfg[new] = cfg[old]
+                del cfg[old]
+                migrated = True
+        return migrated
+
+    def _load_config(self):
+        path = self._config_path()
+        if os.path.exists(path):
+            try:
+                with open(path) as f:
+                    user = json.load(f)
+                migrated = self._migrate_legacy_fields(user)
+                # Be permissive; ignore unknown keys.
+                for k, v in user.items():
+                    if k in self._cfg:
+                        self._cfg[k] = v
+                self.log.info('Loaded aux config from %s' % path)
+                if migrated:
+                    # Persist the upgraded form so future restarts
+                    # see the new field names directly.
+                    try:
+                        self.save_config(self._cfg)
+                        self.log.info(
+                            'Migrated aux.json legacy fields '
+                            '(min_w/max_w -> min_mm/max_mm)')
+                    except Exception:
+                        self.log.warning(
+                            'Could not persist aux.json migration')
+            except Exception:
+                self.log.error('Failed to read aux.json: %s'
+                               % traceback.format_exc())
+
+    def save_config(self, cfg):
+        merged = dict(DEFAULTS)
+        # Accept legacy keys from callers that may still send the
+        # old names (older UI bundles, hand-edited POSTs).
+        cfg = dict(cfg)
+        self._migrate_legacy_fields(cfg)
+        for k, v in cfg.items():
+            if k in DEFAULTS:
+                merged[k] = v
+        path = self._config_path()
+        with open(path, 'w') as f:
+            json.dump(merged, f, indent=2)
+        self._cfg = merged
+        self.log.info('Saved aux config')
+        # Push the relevant pieces to the ESP if connected.
+        if self._present:
+            try:
+                self._push_homecfg()
+            except Exception as e:
+                self.log.warning('Could not push HOMECFG after save: %s' % e)
+
+    def get_config(self):
+        return dict(self._cfg)
+
+    # ------------------------------------------------------------------ public
+
+    @property
+    def enabled(self):
+        return bool(self._cfg.get('enabled', False))
+
+    @property
+    def present(self):
+        return self._present
+
+    @property
+    def homed(self):
+        return self._homed
+
+    @property
+    def position_mm(self):
+        return self._steps_to_mm(self._pos_steps)
+
+    def set_state_observer(self, fn):
+        """Register a callback invoked after every _publish_state.
+        Used by ExternalAxis to mirror the homed flag into State."""
+        self._state_observer = fn
+
+    def home(self):
+        """Run the homing cycle on the ESP. Blocks until done. Raises on
+        failure. Updates aux_homed and aux_pos.
+
+        The ESP's home_zero is pre-loaded via HOMECFG so when the cycle
+        completes the step counter already corresponds to home_position_mm.
+        That way the homed-state survives a bbctrl restart correctly
+        (we don't need a post-home WPOS write, which would clear HOMED)."""
+        self._require_present()
+        # Make sure home_zero on the ESP matches our current
+        # home_position_mm in case the user just edited config.
+        self._push_homecfg()
+        line = self._rpc('HOME', topic='home', timeout=120.0)
+        # line is the body after '[home] '. Only terminal lines use
+        # the [home] topic now (done / failed); progress is [home_log].
+        if line.startswith('done'):
+            self._pos_steps = self._parse_kv_int(line, 'pos', 0)
+            self._homed = True
+            self._publish_state()
+            return
+        # failure
+        reason = line.split('reason=', 1)[1] if 'reason=' in line else line
+        raise AuxAxisError('Homing failed: %s' % reason)
+
+    def move_abs_mm(self, target_mm):
+        """Move to absolute logical W position (mm). Blocks until done."""
+        self._require_present()
+        self._check_limits(target_mm)
+        target_steps = self._mm_to_steps(target_mm)
+        delta = target_steps - self._pos_steps
+        if delta == 0:
+            return
+        self._do_steps(delta)
+
+    def move_rel_mm(self, delta_mm):
+        """Move by delta mm relative to current position. Blocks until done."""
+        self._require_present()
+        target_mm = self.position_mm + delta_mm
+        self._check_limits(target_mm)
+        target_steps = self._mm_to_steps(target_mm)
+        delta = target_steps - self._pos_steps
+        if delta == 0:
+            return
+        self._do_steps(delta)
+
+    def set_position_mm(self, mm):
+        """Set current W to <mm> without moving (G92-style for W)."""
+        self._require_present()
+        steps = self._mm_to_steps(mm)
+        self._rpc('WPOS %d' % steps, topic='ok', timeout=2.0)
+        self._pos_steps = steps
+        # WPOS clears homed on the ESP; mirror it.
+        self._homed = False
+        self._publish_state()
+
+    def jog_steps(self, steps):
+        """Raw step move bypassing mm conversion and soft limits.
+        Used by manual jog UI when axis isn't homed yet."""
+        self._require_present()
+        if steps == 0:
+            return
+        self._do_steps(int(steps), ignore_limits=True)
+
+    def abort(self):
+        """Cancel any running ESP motion immediately."""
+        if not self._present:
+            return
+        try:
+            # Don't take the RPC lock; ABORT must be able to interrupt.
+            self._send_raw('ABORT')
+        except Exception as e:
+            self.log.warning('ABORT send failed: %s' % e)
+
+    # ---------------------------------------------------------- ATC commands
+    #
+    # The auxcnc firmware drives an AMB 1050 FME-W DI tool changer via
+    # three pneumatic valves on relays 1-3. The ESP runs the timed
+    # sequences itself; the host just kicks them off and waits for the
+    # terminal reply.
+
+    def atc_droptool(self, timeout=30.0):
+        """Eject the current tool. Opens the collet (V1), oscillates the
+        ejector (V2), then re-clamps with a bleed cycle. Blocks until
+        the ESP reports done. Raises on failure."""
+        self._require_present()
+        line = self._rpc('DROPTOOL', topic='droptool', timeout=timeout)
+        if line.startswith('done'):
+            return
+        reason = line.split('reason=', 1)[1] if 'reason=' in line else line
+        raise AuxAxisError('DROPTOOL failed: %s' % reason)
+
+    def atc_grabtool(self, timeout=30.0):
+        """Pick up a tool that's already been seated by the operator.
+        Opens V1 (releases the collet), waits for the operator to insert
+        the holder, then re-clamps with a bleed cycle. Blocks."""
+        self._require_present()
+        line = self._rpc('GRABTOOL', topic='grabtool', timeout=timeout)
+        if line.startswith('done'):
+            return
+        reason = line.split('reason=', 1)[1] if 'reason=' in line else line
+        raise AuxAxisError('GRABTOOL failed: %s' % reason)
+
+    def atc_release(self, timeout=5.0):
+        """Manually open the collet (release-only, no clamp). Use
+        atc_clamp() afterwards once the new holder is in place."""
+        self._require_present()
+        line = self._rpc('RELEASE', topic='release', timeout=timeout)
+        if line.startswith('done'):
+            return
+        reason = line.split('reason=', 1)[1] if 'reason=' in line else line
+        raise AuxAxisError('RELEASE failed: %s' % reason)
+
+    def atc_clamp(self, timeout=10.0):
+        """Manually clamp the collet (run a full bleed cycle). Pairs
+        with atc_release() for two-step manual tool changes."""
+        self._require_present()
+        line = self._rpc('CLAMP', topic='clamp', timeout=timeout)
+        if line.startswith('done'):
+            return
+        reason = line.split('reason=', 1)[1] if 'reason=' in line else line
+        raise AuxAxisError('CLAMP failed: %s' % reason)
+
+    def close(self):
+        self._stop.set()
+        try:
+            if self._sp is not None:
+                self._sp.close()
+        except Exception:
+            pass
+
+    # ------------------------------------------------------------------ guts
+
+    def _require_present(self):
+        if not self.enabled:
+            raise AuxAxisError('Aux axis disabled')
+        if not self._present:
+            raise AuxAxisError('Aux axis not connected')
+
+    def _check_limits(self, target_mm):
+        lo = float(self._cfg['min_mm'])
+        hi = float(self._cfg['max_mm'])
+        if hi <= lo:
+            return  # no limits
+        if target_mm < lo - 1e-6 or target_mm > hi + 1e-6:
+            raise AuxAxisError(
+                'A=%.3f out of soft limits [%.3f, %.3f]' % (target_mm, lo, hi))
+
+    def _mm_to_steps(self, mm):
+        spm = float(self._cfg['steps_per_mm'])
+        sign = 1 if int(self._cfg.get('dir_sign', 1)) >= 0 else -1
+        return int(round(mm * spm * sign))
+
+    def _steps_to_mm(self, steps):
+        spm = float(self._cfg['steps_per_mm']) or 1.0
+        sign = 1 if int(self._cfg.get('dir_sign', 1)) >= 0 else -1
+        return (steps / spm) * sign
+
+    def _do_steps(self, signed_count, ignore_limits=False):
+        max_rate = int(self._cfg['step_max_sps'])
+        accel    = int(self._cfg['step_accel_sps2'])
+        safe_flag = 0 if ignore_limits else 1
+        cmd = 'STEPS %d maxrate=%d accel=%d safe=%d' % (
+            signed_count, max_rate, accel, safe_flag)
+        line = self._rpc(cmd, topic='step', timeout=300.0)
+        # line: "done count=N pos=P limit=L"  or  "aborted count=N pos=P [reason=...]"
+        if line.startswith('done'):
+            self._pos_steps = self._parse_kv_int(line, 'pos', self._pos_steps)
+            self._publish_state()
+            return
+        # aborted
+        self._pos_steps = self._parse_kv_int(line, 'pos', self._pos_steps)
+        self._publish_state()
+        reason = self._parse_kv_str(line, 'reason')
+        if reason == 'limit':
+            self._homed = False
+            raise AuxAxisError('W move aborted by limit switch')
+        raise AuxAxisError('W move aborted: %s' % line)
+
+    def _do_line(self, signed_steps, length_mm,
+                 max_accel_mm_min2, max_jerk_mm_min3,
+                 entry_vel_mm_min, exit_vel_mm_min,
+                 times_min, ignore_limits=False, timeout=300.0):
+        """Run a 7-segment jerk-limited S-curve on the ESP that mirrors
+        gplan/buildbotics' planner output exactly.
+
+        Parameters are in the same units the AVR/gplan use:
+          - length_mm:       absolute travel in mm (>= 0)
+          - max_accel:       mm/min^2
+          - max_jerk:        mm/min^3
+          - entry/exit_vel:  mm/min
+          - times_min:       7-tuple of section durations in minutes
+
+        ignore_limits sets safe=0 on the ESP - used for jog/move
+        endpoints that may run before homing.
+
+        Blocks until the ESP reports done or aborted. Updates the
+        position mirror and re-publishes state on every reply.
+        """
+        if signed_steps == 0 or length_mm <= 0:
+            return
+        if not any(times_min):
+            raise AuxAxisError('LINE rejected: all section times are zero')
+        # Build the LINE command. Float formatting matches the AVR's
+        # printf precision (6 sig figs) - that's well above what the
+        # ESP needs given it integrates into a few thousand 4 ms
+        # segments per move.
+        parts = [
+            'LINE',
+            'steps=%d' % int(signed_steps),
+            'length=%.6f' % float(length_mm),
+            'max_accel=%.6f' % float(max_accel_mm_min2),
+            'max_jerk=%.6f' % float(max_jerk_mm_min3),
+            'entry_vel=%.6f' % float(entry_vel_mm_min),
+            'exit_vel=%.6f' % float(exit_vel_mm_min),
+        ]
+        for i, t in enumerate(times_min):
+            if t and t > 0:
+                parts.append('t%d=%.9f' % (i, float(t)))
+        if ignore_limits:
+            parts.append('safe=0')
+        cmd = ' '.join(parts)
+        line = self._rpc(cmd, topic='line', timeout=timeout)
+        # line: "done pos=P emitted=N" or "aborted pos=P emitted=N reason=..."
+        if line.startswith('done'):
+            self._pos_steps = self._parse_kv_int(line, 'pos', self._pos_steps)
+            self._publish_state()
+            return
+        # aborted
+        self._pos_steps = self._parse_kv_int(line, 'pos', self._pos_steps)
+        self._publish_state()
+        reason = self._parse_kv_str(line, 'reason')
+        if reason == 'limit':
+            self._homed = False
+            raise AuxAxisError('W move aborted by limit switch')
+        raise AuxAxisError('W move aborted: %s' % line)
+
+    # ------------------------------------------------------------ serial I/O
+
+    def _open(self):
+        port = self._cfg['port']
+        baud = int(self._cfg['baud'])
+        try:
+            self._sp = serial.Serial(port, baud, timeout=0.2)
+        except Exception as e:
+            self.log.error('Could not open %s: %s' % (port, e))
+            self._sp = None
+            return
+
+        self.log.info('Opened %s @ %d' % (port, baud))
+        self._reader_thread = threading.Thread(
+            target=self._reader_loop, name='AuxAxis-rx', daemon=True)
+        self._reader_thread.start()
+
+        # Give the ESP a moment to settle, then push HOMECFG and query state.
+        # This runs in a background thread to avoid blocking startup.
+        threading.Thread(target=self._on_connect, daemon=True).start()
+
+    def _on_connect(self):
+        time.sleep(0.5)
+        try:
+            self._push_homecfg()
+            self._refresh_state()
+        except Exception as e:
+            self.log.warning('Aux post-connect setup failed: %s' % e)
+
+    def _push_homecfg(self):
+        c = self._cfg
+        zero_steps = self._mm_to_steps(c['home_position_mm'])
+        # preclear: how far (in steps) the ESP backs off if HOME is
+        # invoked while the limit switch is already tripped. Computed
+        # from home_preclear_mm so the operator configures it in mm.
+        spm = float(c.get('steps_per_mm', 1.0)) or 1.0
+        preclear_steps = int(round(abs(float(c['home_preclear_mm'])) * spm))
+        cmd = ('HOMECFG dir=%s fast=%d slow=%d backoff=%d maxtravel=%d '
+               'zero=%d accel=%d step_max=%d step_start=%d limit_low=%d '
+               'preclear=%d') % (
+            c['home_dir'],
+            int(c['home_fast_sps']),
+            int(c['home_slow_sps']),
+            int(c['home_backoff_steps']),
+            int(c['home_maxtravel_steps']),
+            int(zero_steps),
+            int(c['step_accel_sps2']),
+            int(c['step_max_sps']),
+            int(c['step_start_sps']),
+            1 if c['limit_low'] else 0,
+            preclear_steps,
+        )
+        self._rpc(cmd, topic='homecfg', timeout=3.0)
+
+    def _refresh_state(self):
+        try:
+            r = self._rpc('WPOS?', topic='wpos', timeout=2.0)
+            self._pos_steps = int(r.strip())
+        except Exception:
+            pass
+        # Force the host to start unhomed regardless of what the ESP
+        # remembers from a prior session. The ESP's homed flag survives
+        # bbctrl restarts (since the ESP itself wasn't power-cycled),
+        # but the host's planner offsets and DRO position get reset to
+        # zero on bbctrl boot. Trusting the ESP's homed flag would mean
+        # the user thinks A is homed at the wrong work-coord origin
+        # (offset_a=0 but ESP physically at home_position_mm). Sending
+        # UNHOME forces the user to re-home explicitly, which sets up
+        # the offset and gplan state correctly via the homing path in
+        # Mach.home.
+        try:
+            self._rpc('UNHOME', topic='ok', timeout=2.0)
+            self._homed = False
+        except Exception:
+            # Fall back to whatever HOMED? says - but treat any
+            # missing UNHOME support as "trust ESP's flag" so we
+            # don't break older firmware.
+            try:
+                r = self._rpc('HOMED?', topic='homed', timeout=2.0)
+                self._homed = (r.strip() == '1')
+            except Exception:
+                pass
+        self._publish_state()
+
+    def _reader_loop(self):
+        buf = b''
+        while not self._stop.is_set():
+            sp = self._sp
+            if sp is None:
+                time.sleep(0.5)
+                continue
+            try:
+                chunk = sp.read(256)
+            except Exception as e:
+                self.log.warning('Aux serial read error: %s' % e)
+                time.sleep(0.5)
+                continue
+            if not chunk:
+                continue
+            buf += chunk
+            while True:
+                nl = buf.find(b'\n')
+                if nl < 0:
+                    break
+                line = buf[:nl].rstrip(b'\r').decode('utf-8', errors='replace')
+                buf = buf[nl+1:]
+                self._on_line(line)
+
+    def _on_line(self, line):
+        if not line:
+            return
+        # Boot banner -> reset homed flag.
+        if line.startswith('[boot]'):
+            self.log.warning('Aux ESP booted: %s' % line)
+            self._homed = False
+            self._present = True
+            self._publish_state()
+            self.ctrl.state.add_message(
+                'Auxiliary axis controller restarted - re-home before use')
+            return
+
+        # Topic dispatch: "[topic] body..."
+        if line.startswith('[') and ']' in line:
+            rb = line.index(']')
+            topic = line[1:rb]
+            body = line[rb+1:].lstrip()
+            # Mark present on first known topic.
+            if not self._present:
+                self._present = True
+                self._publish_state()
+            # Match against the head of the pending queue.
+            with self._pending_cv:
+                if (self._pending_topics
+                        and topic in self._pending_topics[0]):
+                    # Pop and deliver
+                    self._pending_topics.pop(0)
+                    self._pending_replies.append(body)
+                    self._pending_cv.notify_all()
+                    return
+            # Async informational line; just log.
+            self.log.info('aux: %s' % line)
+        else:
+            self.log.info('aux: %s' % line)
+
+    def _send_raw(self, cmd):
+        sp = self._sp
+        if sp is None:
+            raise AuxAxisError('Serial not open')
+        if not cmd.endswith('\n'):
+            cmd = cmd + '\n'
+        sp.write(cmd.encode('utf-8'))
+        sp.flush()
+
+    def _rpc(self, cmd, topic, timeout=5.0):
+        """Send `cmd`, wait for a reply line whose topic is in `topic`.
+        topic may be a single string or a tuple/list of acceptable topics
+        (e.g. ('home', 'err'))."""
+        if isinstance(topic, str):
+            topics = (topic, 'err')
+        else:
+            topics = tuple(topic) + ('err',)
+
+        with self._sp_lock:
+            with self._pending_cv:
+                self._pending_topics.append(topics)
+                self._pending_replies = []  # reset
+            self.log.info('aux >> %s' % cmd.strip())
+            self._send_raw(cmd)
+
+            deadline = time.time() + timeout
+            with self._pending_cv:
+                while not self._pending_replies:
+                    remaining = deadline - time.time()
+                    if remaining <= 0:
+                        # Drop the pending slot so we don't capture a
+                        # late reply meant for the next caller.
+                        try:
+                            self._pending_topics.remove(topics)
+                        except ValueError:
+                            pass
+                        raise AuxAxisError(
+                            'Timeout waiting for %s reply to "%s"'
+                            % (topics, cmd.strip()))
+                    self._pending_cv.wait(timeout=remaining)
+                reply = self._pending_replies.pop(0)
+            self.log.info('aux << %s' % reply)
+            if reply.startswith('err') or reply.startswith('error'):
+                raise AuxAxisError('ESP error: %s' % reply)
+            return reply
+
+    @staticmethod
+    def _parse_kv_int(line, key, default=0):
+        # Parse "key=N" (signed integer) out of a line.
+        for tok in line.split():
+            if tok.startswith(key + '='):
+                try:
+                    return int(tok.split('=', 1)[1])
+                except ValueError:
+                    return default
+        return default
+
+    @staticmethod
+    def _parse_kv_str(line, key, default=''):
+        for tok in line.split():
+            if tok.startswith(key + '='):
+                return tok.split('=', 1)[1]
+        return default
+
+    # ------------------------------------------------------------ state push
+
+    def _publish_state(self):
+        st = self.ctrl.state
+        try:
+            st.set('aux_present', bool(self._present))
+            st.set('aux_homed',   bool(self._homed))
+            st.set('aux_pos',     round(self.position_mm, 4))
+            st.set('aux_enabled', bool(self.enabled))
+        except Exception:
+            # During very early startup, state may not be ready.
+            pass
+        # Notify the external-axis layer so it can mirror state
+        # (e.g. homed flag) into the synthetic motor vars.
+        observer = getattr(self, '_state_observer', None)
+        if observer is not None:
+            try:
+                observer()
+            except Exception:
+                pass

src/py/bbctrl/AuxPreprocessor.py

@@ -0,0 +1,400 @@
+################################################################################
+#
+# AuxPreprocessor - rewrite ATC M-codes into hook calls
+#
+# History
+# -------
+# v1: rewrote W tokens into (MSG,HOOK:aux:N) lines because the bbctrl
+#     planner only understood XYZABC and the W axis was driven via a
+#     side-channel.
+# v2: W is now exposed to gplan as a virtual A axis (see ExternalAxis),
+#     so gplan handles W motion natively. The preprocessor no longer
+#     touches W tokens. ATC pneumatics still go through the hook
+#     channel because they're events, not motion.
+#
+# What this still does
+# --------------------
+# Maps four user-defined M-codes onto pneumatic-tool-changer events:
+#
+#   M100  DROPTOOL  -> (MSG,HOOK:droptool:)
+#   M101  GRABTOOL  -> (MSG,HOOK:grabtool:)
+#   M102  RELEASE   -> (MSG,HOOK:release:)
+#   M103  CLAMP     -> (MSG,HOOK:clamp:)
+#
+# M100-M103 are in LinuxCNC/Buildbotics' user-defined range, so the
+# planner won't error if the codes leak through unrewritten - it just
+# won't *do* anything. We strip them out and emit the matching hook
+# line in their place.
+#
+# The preprocessor is intentionally conservative: anything it doesn't
+# understand is left alone.
+#
+################################################################################
+
+import os
+import re
+import shutil
+import tempfile
+
+
+# Strip line comments so we don't get fooled by "(M100 not really)".
+_PAREN_COMMENT_RE = re.compile(r'\([^)]*\)')
+
+# ATC pneumatics M-codes mapped onto hook events.
+_ATC_M_CODES = {
+    100: 'droptool',
+    101: 'grabtool',
+    102: 'release',
+    103: 'clamp',
+}
+_ATC_M_RE = re.compile(
+    r'(?<![A-Za-z_0-9])[Mm]\s*0*(' +
+    '|'.join(str(n) for n in _ATC_M_CODES) +
+    r')(?![\w.])'
+)
+
+# Detect a W axis token. We no longer rewrite W to A automatically;
+# instead we warn so the user knows their old gcode needs migration.
+# (The W support was removed when the axis was integrated as a real
+# A axis through gplan.)
+_W_TOKEN_RE = re.compile(r'(?<![A-Za-z_0-9])[Ww]\s*[-+]?\d*\.?\d+')
+
+# Match a single axis word (letter + optional whitespace + signed decimal)
+# for Z, A, X, Y. Used to extract modal targets while preserving the
+# original line for emission. We deliberately ignore I/J/K/R (arc params)
+# because they're not endpoints.
+_AXIS_TOKEN_RES = {
+    'z': re.compile(r'(?<![A-Za-z_0-9])[Zz]\s*([-+]?\d*\.?\d+)'),
+    'a': re.compile(r'(?<![A-Za-z_0-9])[Aa]\s*([-+]?\d*\.?\d+)'),
+    'x': re.compile(r'(?<![A-Za-z_0-9])[Xx]\s*([-+]?\d*\.?\d+)'),
+    'y': re.compile(r'(?<![A-Za-z_0-9])[Yy]\s*([-+]?\d*\.?\d+)'),
+}
+_G_CODE_RE = re.compile(r'(?<![A-Za-z_0-9])[Gg]\s*0*(\d+(?:\.\d+)?)')
+
+
+class AuxPreprocessorError(Exception):
+    pass
+
+
+class AuxPreprocessor(object):
+    def __init__(self, log=None, coupling=None):
+        """`coupling`, when supplied, enables Z-A coupling injection.
+        Expected shape:
+            {
+              'enabled':       bool,
+              'clearance_mm':  float,   # max (A_wc - Z_wc)
+              'a_initial_wc':  float,   # A's work-coord position at
+                                        # file start (typically 0 if
+                                        # operator zeroed at home)
+              'z_initial_wc':  float,   # Z's work-coord position at
+                                        # file start (typically 0)
+            }
+        Pass None to disable injection (preprocessor still rewrites
+        ATC M-codes)."""
+        self.log = log
+        self._w_warned = False
+        self._coupling = coupling if (coupling and
+                                       coupling.get('enabled')) else None
+        # Modal state used while scanning the file.
+        if self._coupling is not None:
+            self._a_wc = float(coupling.get('a_initial_wc', 0.0))
+            self._z_wc = float(coupling.get('z_initial_wc', 0.0))
+            self._K = float(coupling.get('clearance_mm', 0.0))
+        else:
+            self._a_wc = 0.0
+            self._z_wc = 0.0
+            self._K = 0.0
+        self._g91_warned = False
+        # Distance mode: True for absolute (G90), False for incremental
+        # (G91). Per RS274 the modal default at start is G90.
+        self._g90 = True
+
+    def _info(self, msg):
+        if self.log: self.log.info(msg)
+
+    def _warn(self, msg):
+        if self.log: self.log.warning(msg)
+
+    # ------------------------------------------------------------------ scan
+
+    @staticmethod
+    def file_uses_aux(path, coupling=None):
+        """Quick check: does this file contain anything the preprocessor
+        would rewrite? Returns True for ATC M-codes always, and for
+        any Z/A move if coupling is enabled (we have to scan to know
+        whether injection is needed, so any motion file qualifies)."""
+        couple_active = bool(coupling and coupling.get('enabled'))
+        try:
+            with open(path, 'r', encoding='utf-8', errors='replace') as f:
+                for line in f:
+                    code = _PAREN_COMMENT_RE.sub('', line)
+                    code = code.split(';', 1)[0]
+                    if _ATC_M_RE.search(code):
+                        return True
+                    if couple_active:
+                        if _AXIS_TOKEN_RES['z'].search(code) or \
+                                _AXIS_TOKEN_RES['a'].search(code):
+                            return True
+        except Exception:
+            pass
+        return False
+
+    # Backwards-compat alias.
+    file_uses_w = file_uses_aux
+
+    # ------------------------------------------------------------------ Z-A coupling
+    #
+    # Track modal Z and A targets across the file. Whenever a line
+    # would put A above Z by more than `clearance_mm` (i.e. A_wc -
+    # Z_wc > K), we inject `G0 A<safe>` immediately before it so A is
+    # already at the safe position when Z descends. The injected move
+    # uses G0 (rapid) so it's quick.
+    #
+    # Endpoint-only check: gplan plans line endpoints. As long as
+    # (target_A_wc - target_Z_wc) <= K, the trajectory stays safe
+    # because Z's *minimum* during a single line is its endpoint (Z
+    # moves monotonically along a single line block in absolute
+    # mode) and A is held at the pre-positioned value during the move.
+
+    def _extract_g_codes(self, code):
+        """Return the set of G-codes referenced on `code`. Numeric
+        only, e.g. {0, 1, 90, 17}. Used to track modal state."""
+        out = set()
+        for m in _G_CODE_RE.finditer(code):
+            try:
+                out.add(int(float(m.group(1))))
+            except Exception:
+                pass
+        return out
+
+    def _extract_axis(self, axis, code):
+        """Return the last value of `axis` token on `code`, or None."""
+        rx = _AXIS_TOKEN_RES.get(axis)
+        if rx is None:
+            return None
+        last = None
+        for m in rx.finditer(code):
+            try:
+                last = float(m.group(1))
+            except Exception:
+                pass
+        return last
+
+    def _maybe_inject_a_down(self, code, fout):
+        """Inspect `code` (with comments stripped) for an upcoming Z
+        descent; emit a `G0 A<safe>` line on `fout` if needed and
+        update self._a_wc accordingly. Returns True if anything was
+        injected.
+
+        On a violation that cannot be fixed by lowering A (e.g. the
+        operator wrote `G0 A0` while Z is too deep), raise
+        AuxPreprocessorError so the file load surfaces the problem -
+        per the rule we agreed: error, don't silently insert a Z-up.
+        """
+        if self._coupling is None:
+            return False
+
+        # Distance mode tracking.
+        gs = self._extract_g_codes(code)
+        if 90 in gs: self._g90 = True
+        if 91 in gs:
+            if self._g90 and not self._g91_warned:
+                self._warn(
+                    'AuxPreprocessor: G91 (incremental mode) detected; '
+                    'Z-A coupling injection is disabled for the rest of '
+                    'the file. The runtime check still applies.')
+                self._g91_warned = True
+            self._g90 = False
+
+        # G92 sets coordinate offsets. The new modal value of an
+        # axis is whatever value follows on the same word (e.g.
+        # G92 A0 sets A_wc = 0). Apply that and skip injection.
+        if 92 in gs:
+            new_a = self._extract_axis('a', code)
+            new_z = self._extract_axis('z', code)
+            if new_a is not None: self._a_wc = new_a
+            if new_z is not None: self._z_wc = new_z
+            return False
+
+        # In incremental mode we can still track approximately, but
+        # the user has been warned; skip injection.
+        if not self._g90:
+            return False
+
+        new_z_target = self._extract_axis('z', code)
+        new_a_target = self._extract_axis('a', code)
+        if new_z_target is None and new_a_target is None:
+            return False
+
+        # Modal values after the line executes.
+        a_after = new_a_target if new_a_target is not None else self._a_wc
+        z_after = new_z_target if new_z_target is not None else self._z_wc
+
+        eps = 1e-4
+        if a_after - z_after <= self._K + eps:
+            # Move is safe as authored. Update modal state.
+            self._a_wc = a_after
+            self._z_wc = z_after
+            return False
+
+        # Violation. Two cases:
+        #
+        #   (a) The line lowers Z (z_after < self._z_wc) and A is
+        #       held or moved upward, so A needs to drop to keep up.
+        #       We can fix this by pre-positioning A at z_after + K
+        #       BEFORE the line - at which point gplan's plan for the
+        #       line is safe at every point along it.
+        #
+        #   (b) The line raises A above the safe band while Z is
+        #       held (z_after >= self._z_wc) - i.e. the operator
+        #       wrote `G0 A0` while Z is parked deep. Auto-injecting
+        #       a Z-up here is unsafe (Z could swing into a fixture
+        #       or the part) so we error out and let the operator
+        #       author the lift.
+
+        safe_a = z_after + self._K
+
+        # If the line itself targets an A above the safe band, the
+        # endpoint violates the rule no matter what we pre-position.
+        # Refuse rather than emit something that runs the gantry into
+        # the tool.
+        if new_a_target is not None and new_a_target > safe_a + eps:
+            raise AuxPreprocessorError(
+                'Z-A coupling violation: line targets A=%.3f at '
+                'Z=%.3f, but max A allowed is %.3f (clearance %.3f). '
+                'Lower the A target or add a Z-up move first.' % (
+                    new_a_target, z_after, safe_a, self._K))
+
+        # If the line raises A above the current safe band but Z
+        # isn't dropping with it (no Z target on the line, or Z stays
+        # put), the violation is the operator's A-up, not a Z-down.
+        # Refuse rather than insert a Z-up (which could swing through
+        # a fixture or part).
+        if (new_a_target is not None and
+                new_a_target > self._a_wc + eps and
+                new_z_target is None):
+            raise AuxPreprocessorError(
+                'Z-A coupling violation at line raising A to %.3f '
+                'while Z is at %.3f (max A allowed is %.3f given '
+                'clearance %.3f). Add a Z-up move first.' % (
+                    new_a_target, z_after, safe_a, self._K))
+
+        # Case (a): pre-position A.
+        # Don't move A *up* as part of pre-position - if the safe
+        # value is above where A already is, we'd lift A into a
+        # potential collision elsewhere. In practice safe_a < a_wc
+        # whenever we get here (otherwise no violation), but assert
+        # to be sure.
+        if safe_a > self._a_wc + eps:
+            raise AuxPreprocessorError(
+                'Z-A coupling: cannot fix line by lowering A '
+                '(safe A = %.3f > current A = %.3f).' % (
+                    safe_a, self._a_wc))
+        fout.write('(injected by AuxPreprocessor: Z-A coupling)\n')
+        fout.write('G0 A%.4f\n' % safe_a)
+        self._a_wc = safe_a
+        # Don't update z_wc yet - the original line will do that
+        # when it runs. But our modal copy must reflect the post-line
+        # value so subsequent injections compute correctly.
+        self._z_wc = z_after
+        # If the original line also moved A, our pre-positioning
+        # supersedes it (we overwrite a_wc above with safe_a then
+        # the original line's A target may push it back up). Update
+        # a_wc to the line's authored A value so further checks see
+        # the post-line state.
+        if new_a_target is not None:
+            self._a_wc = new_a_target
+        return True
+
+    # ------------------------------------------------------------------ run
+
+    def process(self, src_path, dst_path):
+        """Read src_path, write rewritten G-code to dst_path. Returns
+        True if any rewrite happened."""
+        rewrote_any = False
+
+        with open(src_path, 'r', encoding='utf-8', errors='replace') as fin, \
+                open(dst_path, 'w', encoding='utf-8') as fout:
+            for raw in fin:
+                line = raw.rstrip('\n')
+
+                # Comment-only or blank lines pass through verbatim.
+                code = _PAREN_COMMENT_RE.sub('', line)
+                code = code.split(';', 1)[0]
+                if not code.strip():
+                    fout.write(raw)
+                    continue
+
+                # Warn (once) if the file still uses W tokens. The
+                # standard way is now G1 A<value>; old files must be
+                # migrated by hand.
+                if (not self._w_warned) and _W_TOKEN_RE.search(code):
+                    self._warn('Found W axis token in gcode; W is no '
+                               'longer recognized by bbctrl. Use A '
+                               'instead. (warning suppressed for '
+                               'subsequent W tokens in this file)')
+                    self._w_warned = True
+
+                # Z-A coupling injection BEFORE the line is emitted.
+                if self._maybe_inject_a_down(code, fout):
+                    rewrote_any = True
+
+                # ATC M-codes (M100-M103). Each ATC M-code on the line
+                # is replaced with its (MSG,HOOK:<event>:) line and
+                # stripped from the residual.
+                atc_matches = list(_ATC_M_RE.finditer(line))
+                if atc_matches:
+                    rewrote_any = True
+                    for m in atc_matches:
+                        try: num = int(m.group(1))
+                        except ValueError: continue
+                        event = _ATC_M_CODES.get(num)
+                        if event:
+                            fout.write('(MSG,HOOK:%s:)\n' % event)
+                    line = _ATC_M_RE.sub('', line)
+                    code = _PAREN_COMMENT_RE.sub('', line)
+                    code = code.split(';', 1)[0]
+                    if not code.strip():
+                        # Nothing meaningful left; preserve any trailing
+                        # comment text but skip empty lines.
+                        rest = line.rstrip()
+                        if rest:
+                            fout.write(rest + '\n')
+                        continue
+                    # Other gcode remains on the line - emit it.
+                    fout.write(line + '\n')
+                    continue
+
+                # No rewrite needed.
+                fout.write(raw)
+
+        return rewrote_any
+
+
+def preprocess_file(src_path, log=None, coupling=None, **_unused):
+    """Convenience: rewrite src_path in place if it contains ATC
+    M-codes or needs Z-A coupling injection. Returns True if the
+    file was rewritten.
+
+    `coupling` is an optional dict (see AuxPreprocessor.__init__).
+    Extra keyword args are accepted for backwards compat (the old
+    w_first arg is no longer used)."""
+    if not AuxPreprocessor.file_uses_aux(src_path, coupling=coupling):
+        return False
+    pre = AuxPreprocessor(log=log, coupling=coupling)
+    fd, tmp = tempfile.mkstemp(prefix='auxpre_', suffix='.nc',
+                               dir=os.path.dirname(src_path) or None)
+    os.close(fd)
+    try:
+        rewrote = pre.process(src_path, tmp)
+        if rewrote:
+            shutil.move(tmp, src_path)
+            return True
+        os.unlink(tmp)
+        return False
+    except Exception:
+        try:
+            os.unlink(tmp)
+        except OSError:
+            pass
+        raise

src/py/bbctrl/Camera.py

@@ -468,8 +468,7 @@ class VideoHandler(web.RequestHandler):
         self.camera = app.camera
 
 
-    @web.asynchronous
-    def get(self):
+    async def get(self):
         self.request.connection.stream.max_write_buffer_size = 10000
 
         self.set_header('Cache-Control', 'no-store, no-cache, must-revalidate, '

src/py/bbctrl/Comm.py

@@ -223,6 +223,10 @@ class Comm(object):
                     self.ctrl.mach.process_log(msg)
                 elif 'firmware' in msg:
                     self.log.info('AVR firmware rebooted')
+                    try:
+                        import bbctrl.Trace as _T
+                        _T.mark('avr.firmware_rebooted')
+                    except Exception: pass
                     self.connect()
                 else:
                     self._update_state(msg)

src/py/bbctrl/Config.py

@@ -216,6 +216,32 @@ class Config(object):
                 defaults = json.load(f)
                 config['selected-tool-settings'] = defaults['selected-tool-settings'];
 
+        # Auxiliary axis nomenclature: rename W -> A in macro names and
+        # filenames. The auxcnc-driven stepper has been integrated into
+        # gplan as A since the option-b migration; old configs may
+        # still carry W Down/W Up macro entries pointing at
+        # w_down.nc/w_up.nc which were renamed on disk to a_down.nc /
+        # a_up.nc. Migrate idempotently on every load so a stale
+        # in-memory copy can never reintroduce the old names.
+        macros = config.get('macros') if isinstance(config, dict) else None
+        if isinstance(macros, list):
+            renames = {
+                'w_down.nc': 'a_down.nc',
+                'w_up.nc':   'a_up.nc',
+            }
+            display_renames = {
+                'W Down': 'A Down',
+                'W Up':   'A Up',
+            }
+            for m in macros:
+                if not isinstance(m, dict): continue
+                fn = m.get('file_name')
+                if isinstance(fn, str) and fn in renames:
+                    m['file_name'] = renames[fn]
+                nm = m.get('name')
+                if isinstance(nm, str) and nm in display_renames:
+                    m['name'] = display_renames[nm]
+
         config['version'] = self.version.split('b')[0]
         config['full_version'] = self.version
 

src/py/bbctrl/Ctrl.py

@@ -28,10 +28,12 @@
 import os
 import time
 import bbctrl
+import bbctrl.Trace as Trace
 
 
 class Ctrl(object):
     def __init__(self, args, ioloop, id):
+        Trace.mark('ctrl.init.start', id=id or '<default>')
         self.args = args
         self.ioloop = bbctrl.IOLoop(ioloop)
         self.id = id
@@ -43,31 +45,65 @@ class Ctrl(object):
         if args.demo: log_path = self.get_path(filename = 'bbctrl.log')
         else: log_path = args.log
         self.log = bbctrl.log.Log(args, self.ioloop, log_path)
+        Trace.mark('ctrl.log_open')
 
         self.state = bbctrl.State(self)
         self.config = bbctrl.Config(self)
+        Trace.mark('ctrl.state_config')
 
         self.log.get('Ctrl').info('Starting %s' % self.id)
 
         try:
-            if args.demo: self.avr = bbctrl.AVREmu(self)
-            else: self.avr = bbctrl.AVR(self)
+            with Trace.span('ctrl.avr'):
+                if args.demo: self.avr = bbctrl.AVREmu(self)
+                else: self.avr = bbctrl.AVR(self)
 
-            self.i2c = bbctrl.I2C(args.i2c_port, args.demo)
-            self.lcd = bbctrl.LCD(self)
-            self.mach = bbctrl.Mach(self, self.avr)
-            self.preplanner = bbctrl.Preplanner(self)
-            if not args.demo: self.jog = bbctrl.Jog(self)
-            self.pwr = bbctrl.Pwr(self)
+            with Trace.span('ctrl.i2c'):
+                self.i2c = bbctrl.I2C(args.i2c_port, args.demo)
+            with Trace.span('ctrl.lcd'):
+                self.lcd = bbctrl.LCD(self)
+            with Trace.span('ctrl.mach'):
+                self.mach = bbctrl.Mach(self, self.avr)
+            with Trace.span('ctrl.preplanner'):
+                self.preplanner = bbctrl.Preplanner(self)
+            if not args.demo:
+                with Trace.span('ctrl.jog'):
+                    self.jog = bbctrl.Jog(self)
+            with Trace.span('ctrl.pwr'):
+                self.pwr = bbctrl.Pwr(self)
+            with Trace.span('ctrl.hooks'):
+                self.hooks = bbctrl.Hooks(self)
+            with Trace.span('ctrl.aux'):
+                self.aux = bbctrl.AuxAxis(self)
+            with Trace.span('ctrl.ext_axis'):
+                # ExternalAxis exposes the auxcnc ESP stepper as a
+                # virtual A axis that gplan handles natively. Created
+                # unconditionally so State sees the synthetic motor
+                # vars even when aux is disabled (kept inert in that
+                # case via ext_axis.enabled).
+                axis_letter = self.aux._cfg.get('axis_letter', 'a')
+                self.ext_axis = bbctrl.ExternalAxis(
+                    self, self.aux, axis_letter=axis_letter)
+                # Hook AuxAxis post-publish callback so homed flag
+                # mirrors into State after homing.
+                self.aux.set_state_observer(
+                    self.ext_axis.refresh_homed)
+            self._register_aux_hooks()
 
-            self.mach.connect()
+            with Trace.span('ctrl.mach.connect'):
+                self.mach.connect()
 
             self.lcd.add_new_page(bbctrl.MainLCDPage(self))
             self.lcd.add_new_page(bbctrl.IPLCDPage(self.lcd))
 
             os.environ['GCODE_SCRIPT_PATH'] = self.get_upload()
 
-        except Exception: self.log.get('Ctrl').exception('Internal error: Control initialization failed')
+            Trace.mark('ctrl.init.end')
+            Trace.sd_notify('STATUS=ctrl initialized\n')
+
+        except Exception:
+            Trace.mark('ctrl.init.error')
+            self.log.get('Ctrl').exception('Internal error: Control initialization failed')
 
 
     def __del__(self): print('Ctrl deleted')
@@ -109,8 +145,61 @@ class Ctrl(object):
         self.preplanner.start()
 
 
+    def _register_aux_hooks(self):
+        """Wire up auxcnc HOOK: events to AuxAxis methods.
+
+        v2: motion hooks (aux/aux_rel/aux_home/aux_setzero) are
+        retired now that the W axis is integrated through gplan as
+        a virtual A axis (see ExternalAxis). Only the ATC pneumatic
+        hooks remain - those are events, not motion.
+
+        For backwards compatibility with files that still contain
+        (MSG,HOOK:aux_home:) (e.g. older preprocessed gcode), keep
+        an aux_home alias that routes to the standard ext_axis homing
+        path."""
+        log = self.log.get('AuxAxis')
+
+        def _hook_aux_home(ctx):
+            # Legacy: route to the standard external-axis homing.
+            if self.ext_axis is not None and self.ext_axis.enabled:
+                self.ext_axis.home()
+            else:
+                self.aux.home()
+
+        def _hook_droptool(ctx):  self.aux.atc_droptool()
+        def _hook_grabtool(ctx):  self.aux.atc_grabtool()
+        def _hook_release(ctx):   self.aux.atc_release()
+        def _hook_clamp(ctx):     self.aux.atc_clamp()
+
+        # Legacy alias for older gcode that used aux_home.
+        self.hooks.register_internal('aux_home',    _hook_aux_home,
+                                     block_unpause=True, auto_resume=True,
+                                     timeout=180)
+
+        # ATC pneumatics. block_unpause + auto_resume so a program
+        # using M100/M101/M102/M103 pauses at the right point and
+        # resumes once the sequence is done.
+        self.hooks.register_internal('droptool',    _hook_droptool,
+                                     block_unpause=True, auto_resume=True,
+                                     timeout=60)
+        self.hooks.register_internal('grabtool',    _hook_grabtool,
+                                     block_unpause=True, auto_resume=True,
+                                     timeout=60)
+        self.hooks.register_internal('release',     _hook_release,
+                                     block_unpause=True, auto_resume=True,
+                                     timeout=10)
+        self.hooks.register_internal('clamp',       _hook_clamp,
+                                     block_unpause=True, auto_resume=True,
+                                     timeout=15)
+        log.info('Aux hooks registered')
+
+
     def close(self):
         self.log.get('Ctrl').info('Closing %s' % self.id)
         self.ioloop.close()
         self.avr.close()
         self.mach.planner.close()
+        try: self.ext_axis.close()
+        except Exception: pass
+        try: self.aux.close()
+        except Exception: pass

src/py/bbctrl/ExternalAxis.py

@@ -0,0 +1,677 @@
+################################################################################
+#
+# ExternalAxis - bridges a logical motorless axis to step generation on
+# the auxcnc ESP, so the Buildbotics planner can drive a stepper that
+# isn't on the AVR.
+#
+# Architecture
+# ------------
+# The bbctrl planner (camotics gplan) handles parsing, units, modal
+# state, soft limits, accel ramping and S-curve timing for axes
+# X, Y, Z, A, B, C. The AVR has 4 motor channels (0-3) and only
+# generates step pulses for axes that have a motor mapped to them.
+# An axis with no mapped motor is fully accepted by the AVR - it
+# updates its internal `ex.position[axis]` and reports `<axis>p` to
+# the host, but no stepper turns.
+#
+# We exploit that: the W stepper is exposed to gplan as A, but no
+# AVR motor maps to A. The planner does all the gcode-level work
+# correctly (G90/G91, soft limits, accel, units, modal feed rate);
+# we intercept the resulting `Cmd.line` blocks in `Planner.__encode`,
+# strip A out, and forward the A delta to the auxcnc ESP as STEPS.
+#
+# To make gplan and State *believe* A is enabled we register a
+# synthetic motor (index 4) into State.vars, populated from
+# aux.json, with `4an=3` (axis A), `4me=1` (enabled), and the
+# usual velocity/accel/jerk/soft-limit vars. State.find_motor and
+# the snapshot projection are extended to walk index 4. Motor-4
+# vars never leave the host (they're not in the AVR's schema) so
+# the AVR is undisturbed.
+#
+# v1 coupling: serialize. If a line has any A delta we wait for
+# the ESP to finish before letting subsequent commands flow. This
+# matches the behaviour of the previous hook-based approach (no
+# XYZ+A blending) but with all the planner's correctness guarantees.
+#
+# v2 could match ESP move duration to the gplan trapezoid time and
+# allow concurrent motion; out of scope for v1.
+#
+################################################################################
+
+import threading
+
+try:
+    from queue import Queue
+except ImportError:
+    from Queue import Queue  # py2 just in case
+
+
+# Synthetic motor index used to expose the external axis to State.
+# The AVR has motors 0..3; we use 4 as a host-only sentinel.
+EXTERNAL_MOTOR_INDEX = 4
+
+# Axis letters in their canonical order; 'a' is index 3.
+_AXIS_LETTERS = 'xyzabc'
+
+
+class ExternalAxisError(Exception):
+    pass
+
+
+class ExternalAxis(object):
+    """Bridge between Planner line blocks and AuxAxis serial RPCs.
+
+    Owns no thread; runs RPC calls inline on whatever thread invokes
+    execute_to_mm / home / abort. The Planner runs `__encode` on its
+    own thread which is allowed to block on planner I/O, so blocking
+    inside the interceptor is fine.
+
+    Position tracking: gplan emits absolute targets in mm; the ESP
+    counts steps relative to home_zero. We mirror the last commanded
+    mm position so subsequent line blocks compute the correct delta.
+    `_pos_mm` is also published as `<axis>p` so DRO updates."""
+
+    def __init__(self, ctrl, aux, axis_letter='a'):
+        self.ctrl = ctrl
+        self.aux = aux
+        self.log = ctrl.log.get('ExternalAxis')
+
+        self.axis_letter = (axis_letter or 'a').lower()[:1]
+        if self.axis_letter not in _AXIS_LETTERS:
+            raise ExternalAxisError(
+                'Invalid external axis letter: %r' % axis_letter)
+        # Index in 'xyzabc' (0..5)
+        self.axis_index = _AXIS_LETTERS.index(self.axis_letter)
+
+        self._busy = threading.Event()
+        # Last absolute mm we committed; None until first move /
+        # homing event syncs us up.
+        self._pos_mm = None
+
+        # Single-slot worker queue: __encode posts (target_mm,) tuples
+        # here; the worker thread runs the ESP RPC. Capacity is
+        # intentionally bounded - if it fills it means motion is
+        # outpacing the ESP and we should backpressure the planner.
+        self._work_q = Queue(maxsize=64)
+        self._stop = threading.Event()
+        self._worker = threading.Thread(
+            target=self._worker_loop,
+            name='ExternalAxis-worker', daemon=True)
+        self._worker.start()
+
+        # Push synthetic motor vars into State so the planner sees
+        # this axis as enabled with proper limits/velocity/accel.
+        self._publish_synthetic_motor()
+        # Also seed <axis>p so the DRO has something to render.
+        self.ctrl.state.set(self.axis_letter + 'p', 0.0)
+
+    # -------------------------------------------------------------- enabled
+
+    @property
+    def enabled(self):
+        try:
+            return bool(self.aux is not None
+                        and self.aux.enabled
+                        and self.aux.present)
+        except Exception:
+            return False
+
+    # -------------------------------------------------------- configuration
+
+    @property
+    def steps_per_mm(self):
+        try:
+            return float(self.aux._cfg.get('steps_per_mm', 25.0))
+        except Exception:
+            return 25.0
+
+    @property
+    def dir_sign(self):
+        try:
+            v = int(self.aux._cfg.get('dir_sign', 1))
+            return -1 if v < 0 else 1
+        except Exception:
+            return 1
+
+    @property
+    def home_position_mm(self):
+        try:
+            return float(self.aux._cfg.get('home_position_mm', 0.0))
+        except Exception:
+            return 0.0
+
+    # ------------------------------------------------------- soft limits
+
+    def _soft_limits(self):
+        """Return (min_mm, max_mm) in machine coords, or (None, None)
+        if soft limits are disabled (max <= min)."""
+        try:
+            lo = float(self.aux._cfg.get('min_mm', 0.0))
+            hi = float(self.aux._cfg.get('max_mm', 0.0))
+        except Exception:
+            return (None, None)
+        if hi <= lo:
+            return (None, None)
+        return (lo, hi)
+
+    def _check_soft_limit(self, target_abs_mm):
+        """Raise ExternalAxisError if target_abs_mm is outside the
+        configured soft limits. Skips the check when the axis isn't
+        homed (matching the standard bbctrl convention that soft
+        limits are gated by homing state) - that lets the user jog
+        away from a stuck position before homing without false
+        rejections.
+
+        Called by both planner-driven motion (enqueue_target_mm) and
+        UI motion (execute_to_mm), so this is the single source of
+        truth regardless of which path triggered the move."""
+        # Honour the homing gate.
+        try:
+            homed = bool(self.aux._homed)
+        except Exception:
+            homed = False
+        if not homed:
+            return
+        lo, hi = self._soft_limits()
+        if lo is None:
+            return
+        # Use a tiny epsilon so floating-point round-trip targets
+        # right at the boundary aren't rejected.
+        eps = 1e-4
+        target = float(target_abs_mm)
+        if target < lo - eps or target > hi + eps:
+            raise ExternalAxisError(
+                '%s axis target %.4f mm is outside soft limits '
+                '[%.3f, %.3f] mm' % (
+                    self.axis_letter.upper(), target, lo, hi))
+
+    # ----------------------------------------------- Z-A coupling
+    #
+    # The auxiliary tool hangs below the Z spindle. Beyond a small
+    # Z descent the two collide unless A drops with Z. The
+    # constraint, in machine coords, is
+    #
+    #     A_machine - Z_machine <= K
+    #     K = (A_home_mm - z_home_mm) + couple_z_clearance_mm
+    #
+    # Enforced before any motion (planner blocks, MDI, jogs). The
+    # AuxPreprocessor injects pre-position A moves into uploaded
+    # files so well-formed gcode runs without having to think about
+    # this. Disabled when couple_z_enabled is false.
+
+    @property
+    def couple_z_enabled(self):
+        try:
+            return bool(self.aux._cfg.get('couple_z_enabled', False))
+        except Exception:
+            return False
+
+    @property
+    def couple_K(self):
+        """Limit constant K (machine-coord units): the maximum value
+        of (A_machine - Z_machine) before the tool collides. Returns
+        None if the rule isn't applicable (coupling disabled or
+        config missing)."""
+        try:
+            cfg = self.aux._cfg
+            clearance = float(cfg.get('couple_z_clearance_mm', 0.0))
+            a_home    = float(cfg.get('home_position_mm', 0.0))
+            z_home    = float(cfg.get('z_home_mm', 0.0))
+            return (a_home - z_home) + clearance
+        except Exception:
+            return None
+
+    @property
+    def couple_clearance_mm(self):
+        """Raw clearance from config: how far Z may travel below its
+        home before A has to start dropping with it. Used by the
+        AuxPreprocessor to inject pre-position A moves into uploaded
+        gcode."""
+        try:
+            return float(self.aux._cfg.get('couple_z_clearance_mm', 0.0))
+        except Exception:
+            return 0.0
+
+    def _z_machine_now(self):
+        """Read Z's current machine position from State, or None if
+        Z isn't homed/reported yet. The AVR reports absolute machine
+        positions in <axis>p; the work-coord display is computed by
+        the UI as zp - offset_z, but here we want machine directly."""
+        try:
+            st = self.ctrl.state
+            zp = st.get('zp', None)
+            if zp is None:
+                return None
+            return float(zp)
+        except Exception:
+            return None
+
+    def _a_machine_now(self):
+        """A's current machine position. ExternalAxis tracks this
+        directly in self._pos_mm (mm in machine coords - we don't
+        apply G92 to A internally; offset_a is informational)."""
+        try:
+            if self._pos_mm is not None:
+                return float(self._pos_mm)
+            # Fall back to whatever the ESP last reported.
+            return float(self.aux.position_mm)
+        except Exception:
+            return None
+
+    def coupling_for_preprocessor(self):
+        """Return the dict the AuxPreprocessor wants for in-file
+        injection, or None when coupling is off. We assume the
+        operator authors gcode in a frame where the at-home position
+        is A_wc=0, Z_wc=0 - which matches our home-zeroed setup.
+        Files that use a different convention will fall through to
+        the runtime check."""
+        if not self.couple_z_enabled:
+            return None
+        return {
+            'enabled':       True,
+            'clearance_mm':  self.couple_clearance_mm,
+            'a_initial_wc':  0.0,
+            'z_initial_wc':  0.0,
+        }
+
+    def check_coupling(self, target_a_machine=None, target_z_machine=None):
+        """Validate that a proposed motion respects the Z-A coupling.
+
+        Each argument is a target *machine* mm position; pass None to
+        keep the current value of that axis.
+
+        Improvement-aware: a move is rejected only when it *worsens*
+        an already-violating state (or moves a healthy state into
+        violation). Pure XY jogs that touch neither Z nor A are not
+        passed through here; jogs that hold Z or A at their current
+        value (gplan emits the unchanged value in `target`) pass
+        because (a-z) doesn't change. Z-up moves while in violation
+        also pass because they reduce (a-z) toward the bound.
+
+        Raises ExternalAxisError on violation. Skipped when coupling
+        is disabled, the aux axis isn't homed, or current positions
+        aren't yet known.
+        """
+        if not self.couple_z_enabled:
+            return
+        try:
+            homed = bool(self.aux._homed)
+        except Exception:
+            homed = False
+        if not homed:
+            return
+        K = self.couple_K
+        if K is None:
+            return
+        a_now = self._a_machine_now()
+        z_now = self._z_machine_now()
+        if a_now is None or z_now is None:
+            return
+        a_after = (float(target_a_machine)
+                   if target_a_machine is not None else a_now)
+        z_after = (float(target_z_machine)
+                   if target_z_machine is not None else z_now)
+        eps = 1e-4
+        gap_after  = a_after - z_after
+        gap_before = a_now   - z_now
+        # Only refuse when (a) the resulting state would violate the
+        # constraint AND (b) the move makes things at least as bad
+        # as the current state. This lets the operator escape an
+        # already-violating state by moving in the right direction
+        # (Z up, A down).
+        if gap_after > K + eps and gap_after > gap_before - eps:
+            raise ExternalAxisError(
+                'Z-A coupling violation: A=%.3f mm and Z=%.3f mm '
+                '(machine) would put A above Z by %.3f mm; max '
+                'allowed is %.3f mm. Drop A or raise Z first.' % (
+                    a_after, z_after, gap_after, K))
+
+    # ----------------------------------------------------------- conversion
+
+    def mm_to_steps_delta(self, delta_mm):
+        return int(round(float(delta_mm) * self.steps_per_mm * self.dir_sign))
+
+    def steps_to_mm(self, steps):
+        return (float(steps) / self.steps_per_mm) * self.dir_sign
+
+    # ---------------------------------------------------- synthetic motor
+
+    def _publish_synthetic_motor(self):
+        """Write motor-4 vars into State so find_motor('a') and
+        get_axis_vector('vm') see A as a real axis. The AVR never
+        sees these (motor index 4 is not in its var schema)."""
+        cfg = self.aux._cfg if self.aux is not None else {}
+        st = self.ctrl.state
+        i = str(EXTERNAL_MOTOR_INDEX)
+
+        # Axis assignment: 'an' is the 0-based axis index in xyzabc.
+        st.set(i + 'an', self.axis_index)
+        # Motor enabled.
+        st.set(i + 'me', 1 if (self.aux and self.aux.enabled) else 0)
+        # Homed flag - cleared until aux reports homed.
+        try:
+            homed = bool(self.aux._homed)
+        except Exception:
+            homed = False
+        st.set(i + 'h', 1 if homed else 0)
+
+        # Velocity / accel / jerk: the planner reads these via
+        # state.get_axis_vector('<code>', SCALE) which multiplies the
+        # stored raw value by SCALE. The bbctrl convention (matching
+        # what motors 0-3 store) is:
+        #   vm: stored in m/min, planner expects mm/min  (scale 1000)
+        #   am: stored in km/min^2, planner expects mm/min^2 (scale 1e6)
+        #   jm: stored in km/min^3, planner expects mm/min^3 (scale 1e6)
+        # Onefinity defaults for XY are vm=10, am=750, jm=1000. We
+        # follow the same convention; aux.json exposes the values in
+        # those user-facing units so they're directly comparable.
+        st.set(i + 'vm', float(cfg.get('max_velocity_m_per_min',  6.0)))
+        st.set(i + 'am', float(cfg.get('max_accel_km_per_min2', 100.0)))
+        st.set(i + 'jm', float(cfg.get('max_jerk_km_per_min3',  500.0)))
+
+        # Soft limits in machine units (mm). State.get_soft_limit_vector
+        # returns these directly, no scaling.
+        st.set(i + 'tn', float(cfg.get('min_mm', 0.0)))
+        st.set(i + 'tm', float(cfg.get('max_mm', 0.0)))
+
+        # home_position / home_travel are exposed as callbacks for
+        # motors 0..3 (see State.__init__). Register the same lazy
+        # callbacks for motor 4 so gplan's resolver lookup
+        # (_<axis>_home_position / _<axis>_home_travel) returns the
+        # right values for the external axis.
+        st.set_callback(
+            i + 'home_position', lambda name: self.home_position_mm)
+        st.set_callback(
+            i + 'home_travel',
+            lambda name: float(self.aux._cfg.get('max_mm', 0.0))
+                       - self.home_position_mm)
+
+        # Misc fields that other code paths might query. Defaults
+        # mirror what the AVR pushes for motors 0-3.
+        st.set(i + 'sa', 1.8)
+        st.set(i + 'mi', 16)
+        st.set(i + 'tr', 4.0)
+        st.set(i + 'sp', 200)
+        st.set(i + 'ic', 0.0)
+        st.set(i + 'dc', 0.0)
+        st.set(i + 'rv', False)
+        st.set(i + 'tc', 1)
+        st.set(i + 'lb', 5)
+        st.set(i + 'ho', 0)
+        st.set(i + 'os', 0)
+        st.set(i + 'oa', False)
+        st.set(i + 'lm', 8)
+        st.set(i + 'lv', 0.1)
+        st.set(i + 'sv', 1.688)
+        st.set(i + 'tv', 1.997)
+        st.set(i + 'lw', 2)   # min-switch
+        st.set(i + 'xw', 2)   # max-switch
+        st.set(i + 'ls', 0)
+        st.set(i + 'xs', 0)
+        st.set(i + 'df', 0)
+
+    def refresh_homed(self):
+        """Called when AuxAxis updates its homed flag. Mirrors into
+        State so is_axis_homed('a') returns the right answer.
+
+        Updates several places at once because different layers read
+        the homed state via different keys:
+          - synthetic motor flag: 4h    (used by snapshot -> a_h)
+          - axis-level flag:      a_homed (used by State.is_axis_homed
+                                           and gplan _a_homed resolver)"""
+        try:
+            homed = bool(self.aux._homed)
+        except Exception:
+            homed = False
+        st = self.ctrl.state
+        st.set(str(EXTERNAL_MOTOR_INDEX) + 'h', 1 if homed else 0)
+        st.set(self.axis_letter + '_homed', bool(homed))
+
+    # ----------------------------------------------------------- line split
+
+    def split_target(self, target):
+        """Pop the external axis out of a target dict and return
+        (target_without_ext, ext_mm_or_None). Both case variants
+        accepted defensively."""
+        if not target:
+            return target, None
+        ax = self.axis_letter
+        new_target = dict(target)
+        ext_mm = new_target.pop(ax, None)
+        if ext_mm is None:
+            ext_mm = new_target.pop(ax.upper(), None)
+        return new_target, ext_mm
+
+    # -------------------------------------------------------- execution API
+
+    def is_busy(self):
+        return self._busy.is_set()
+
+    def execute_to_mm(self, ext_mm):
+        """Synchronously run an external move. Blocks until the ESP
+        reports done. Used by the legacy /api/aux/move and /api/aux/jog
+        endpoints which may want to wait. Most planner-driven motion
+        goes through enqueue_target_mm instead, which is non-blocking.
+
+        Soft limits are enforced here (not just in gplan) because the
+        UI jog/move endpoints don't go through the planner.
+
+        Updates state.<axis>p immediately on completion. For the
+        planner-driven path that goes through enqueue_target_mm, the
+        AVR's own ap reports drive state.<axis>p instead."""
+        if not self.enabled:
+            raise ExternalAxisError(
+                'External axis %r not available (aux disabled or '
+                'not connected)' % self.axis_letter)
+
+        self._check_soft_limit(ext_mm)
+        # Coupling: A is in machine coords directly (we don't apply
+        # a G92 offset to A), so target_a_machine == ext_mm.
+        self.check_coupling(target_a_machine=ext_mm)
+        steps, abs_mm = self._compute_move(ext_mm)
+        if steps == 0:
+            self._pos_mm = abs_mm
+            self.ctrl.state.set(self.axis_letter + 'p', self._pos_mm)
+            return
+
+        self._busy.set()
+        try:
+            self.aux._do_steps(steps, ignore_limits=True)
+            self._pos_mm = abs_mm
+            self.ctrl.state.set(self.axis_letter + 'p', self._pos_mm)
+        finally:
+            self._busy.clear()
+
+    def enqueue_target_mm(self, ext_mm):
+        """Legacy non-blocking variant: post a fixed-rate STEPS move
+        to the worker queue. No longer used by Planner.__encode (which
+        uses enqueue_line for full S-curve mirroring), but kept for
+        UI jog endpoints that don't have planner timing data.
+
+        Soft limits are enforced here (defense in depth on top of
+        gplan)."""
+        if not self.enabled:
+            raise ExternalAxisError(
+                'External axis %r not available' % self.axis_letter)
+        self._check_soft_limit(ext_mm)
+        self.check_coupling(target_a_machine=ext_mm)
+        steps, abs_mm = self._compute_move(ext_mm)
+        # Internal mirror only - drives subsequent delta computation.
+        # state.<axis>p is left to the AVR's status reports.
+        self._pos_mm = abs_mm
+        if steps == 0:
+            return
+        self._work_q.put(('move', steps))
+
+    def enqueue_line(self, ext_mm, max_accel_mm_min2, max_jerk_mm_min3,
+                     entry_vel_mm_min, exit_vel_mm_min, times_ms):
+        """Post a full S-curve LINE block to the ESP worker. Mirrors
+        gplan's planned trajectory exactly (same 7-segment math, same
+        unit system) so the ESP's move duration matches what the AVR
+        would have produced for an A motor.
+
+        Called by Planner.__encode for every line block that touches
+        the external axis.
+
+        Parameters:
+          ext_mm:           absolute target in mm (gplan target['a'])
+          max_accel_mm_min2:from block['max-accel']
+          max_jerk_mm_min3: from block['max-jerk']
+          entry_vel_mm_min: from block['entry-vel'] (typically 0 for
+                            the first block, exit_vel of the prior
+                            block otherwise)
+          exit_vel_mm_min:  from block['exit-vel']
+          times_ms:         7-tuple of section durations in ms
+                            (block['times'] - the same units gplan uses)
+        """
+        if not self.enabled:
+            raise ExternalAxisError(
+                'External axis %r not available' % self.axis_letter)
+        self._check_soft_limit(ext_mm)
+        self.check_coupling(target_a_machine=ext_mm)
+        steps, abs_mm = self._compute_move(ext_mm)
+        delta_mm = abs(abs_mm - (self._pos_mm if self._pos_mm is not None
+                                 else 0.0))
+        # Update internal mirror; AVR drives state.<axis>p.
+        self._pos_mm = abs_mm
+        if steps == 0 or delta_mm <= 0:
+            return
+        # ms -> minutes (the unit gplan/AVR/ESP use internally for
+        # SCurve math).
+        times_min = tuple((t / 60000.0) if t else 0.0 for t in times_ms)
+        self._work_q.put(('line', steps, delta_mm,
+                          float(max_accel_mm_min2),
+                          float(max_jerk_mm_min3),
+                          float(entry_vel_mm_min),
+                          float(exit_vel_mm_min),
+                          times_min))
+
+    def _compute_move(self, ext_mm):
+        """Return (signed_steps, absolute_mm) for a target in mm.
+        Caches first-time position from the ESP."""
+        if self._pos_mm is None:
+            self._pos_mm = self._read_esp_position_mm()
+        delta_mm = float(ext_mm) - self._pos_mm
+        return self.mm_to_steps_delta(delta_mm), float(ext_mm)
+
+    def _worker_loop(self):
+        """Background thread that drains the work queue. RPCs to the
+        ESP are slow (multi-second moves) and must not run on the
+        ioloop thread. We serialize ESP commands here so multiple
+        line-block enqueues for the external axis are processed in
+        the order the planner emitted them."""
+        while not self._stop.is_set():
+            try:
+                op = self._work_q.get(timeout=0.5)
+            except Exception:
+                continue
+            if op is None:
+                continue
+            kind = op[0]
+            try:
+                self._busy.set()
+                if kind == 'move':
+                    steps = op[1]
+                    self.aux._do_steps(steps, ignore_limits=True)
+                elif kind == 'line':
+                    (_, steps, length_mm,
+                     max_accel, max_jerk,
+                     entry_vel, exit_vel,
+                     times_min) = op
+                    self.aux._do_line(
+                        steps, length_mm, max_accel, max_jerk,
+                        entry_vel, exit_vel, times_min,
+                        ignore_limits=True)
+                elif kind == 'home':
+                    self.aux.home()
+                    # _pos_mm and DRO updated by the caller's enqueue.
+            except Exception as e:
+                self.log.error('External axis worker failed on %s: %s'
+                               % (kind, e))
+            finally:
+                self._busy.clear()
+                self._work_q.task_done()
+
+    def wait_idle(self, timeout=None):
+        """Block until the worker queue is empty. Used by callers
+        that need post-motion state to be settled (e.g. homing,
+        stop/abort handlers)."""
+        try:
+            # Queue.join blocks until task_done has been called for
+            # every item put. It does not honour a timeout, so we
+            # poll instead when one is requested.
+            if timeout is None:
+                self._work_q.join()
+                return True
+            import time
+            deadline = time.time() + float(timeout)
+            while time.time() < deadline:
+                if self._work_q.unfinished_tasks == 0:
+                    return True
+                time.sleep(0.05)
+            return False
+        except Exception:
+            return False
+
+    def close(self):
+        self._stop.set()
+        try:
+            self._work_q.put(None, block=False)
+        except Exception:
+            pass
+
+    def home(self):
+        """Run the ESP homing cycle and sync our recorded position
+        to the configured home_position_mm. Blocks; called from
+        Mach.home (which already runs synchronously per axis)."""
+        if not self.enabled:
+            raise ExternalAxisError(
+                'External axis %r not available' % self.axis_letter)
+        # Drain pending moves so we don't home into stale work.
+        self.wait_idle(timeout=30.0)
+        self._busy.set()
+        try:
+            self.aux.home()
+            self._pos_mm = self.home_position_mm
+            self.ctrl.state.set(self.axis_letter + 'p', self._pos_mm)
+            self.refresh_homed()
+        finally:
+            self._busy.clear()
+
+    def abort(self):
+        """Cancel the ESP move and drop pending queued work.
+        Caller (estop / stop handler) is responsible for the
+        planner-side cleanup."""
+        try:
+            if self.aux is not None:
+                self.aux.abort()
+        finally:
+            self._busy.clear()
+        # Drain any pending ops so resume after an abort doesn't
+        # replay stale targets.
+        try:
+            while True:
+                self._work_q.get_nowait()
+                self._work_q.task_done()
+        except Exception:
+            pass
+
+    # ------------------------------------------------------- ESP introspection
+
+    def _read_esp_position_mm(self):
+        """Convert AuxAxis._pos_steps mirror to mm. Falls back to 0."""
+        try:
+            steps = int(self.aux._pos_steps)
+        except Exception:
+            steps = 0
+        return self.steps_to_mm(steps)
+
+    # ---------------------------------------------------------- DRO update
+
+    def sync_dro(self):
+        """Push the current position to State as <axis>p so the DRO
+        reflects what we believe gplan/ESP agreed on. Called after
+        moves; also safe to call from external code."""
+        if self._pos_mm is None:
+            return
+        self.ctrl.state.set(self.axis_letter + 'p', self._pos_mm)

src/py/bbctrl/FileHandler.py

@@ -99,6 +99,27 @@ class FileHandler(bbctrl.APIHandler):
 
             del (self.uploadFile)
 
+            # If the uploaded G-code uses ATC M-codes (M100..M103),
+            # rewrite them into (MSG,HOOK:droptool:) etc so the hook
+            # layer can dispatch them at runtime. The planner accepts
+            # M100-M103 in user-defined range but doesn't *do* anything
+            # with them. Motion in A goes through gplan unchanged - the
+            # auxcnc stepper is exposed as a virtual A axis (see
+            # ExternalAxis).
+            try:
+                from bbctrl.AuxPreprocessor import preprocess_file
+                log = self.get_log('AuxPreprocessor')
+                ext = getattr(self.get_ctrl(), 'ext_axis', None)
+                coupling = (ext.coupling_for_preprocessor()
+                            if ext is not None else None)
+                if preprocess_file(filename.decode('utf8'),
+                                    log=log, coupling=coupling):
+                    log.info('Rewrote upload (ATC / Z-A coupling) in %s'
+                             % self.uploadFilename)
+            except Exception:
+                self.get_log('AuxPreprocessor').exception(
+                    'Aux preprocess failed; uploading unchanged')
+
             self.get_ctrl().preplanner.invalidate(self.uploadFilename)
             self.get_ctrl().state.add_file(self.uploadFilename)
 

src/py/bbctrl/Hooks.py

@@ -0,0 +1,454 @@
+################################################################################
+#
+# Hooks - External event triggers during G-code execution
+#
+# Integrates with the controller's pause/unpause cycle to run external
+# actions (webhooks, scripts) at specific points during G-code execution.
+#
+# ## How tool-change hooks work (the important one):
+#
+#   G-code: T5 M6
+#
+#   1. Planner replaces M6 with tool-change override G-code (configurable).
+#      Default: "M0 M6 (MSG, Change tool)"
+#
+#   2. Planner emits: set(tool,5), pause(program), message("Change tool")
+#      These are sent to the AVR as serial commands.
+#
+#   3. AVR finishes current move, enters HOLDING state.
+#      Reports back: xx=HOLDING, pr="Program pause"
+#
+#   4. Pi: Mach._update() sees HOLDING, flushes CommandQueue.
+#      CommandQueue executes callbacks: state.set('tool', 5) fires.
+#
+#   5. Hooks._on_state_change() sees tool changed.
+#      Sets self._hook_busy = True, runs the hook in a thread.
+#      While _hook_busy, Mach.unpause() is blocked via can_unpause().
+#
+#   6. Machine sits in HOLDING. UI shows "Change tool" message.
+#      User cannot resume yet (unpause is gated).
+#
+#   7. Hook thread finishes (toolchanger done). Sets _hook_busy = False.
+#      If auto_resume is set, calls unpause automatically.
+#      Otherwise user clicks Continue in UI.
+#
+#   8. Mach.unpause() → planner.restart() → AVR UNPAUSE → motion resumes.
+#
+# ## Configuration (hooks.json):
+#
+#   {
+#     "tool-change": {
+#       "type": "webhook",
+#       "url": "http://toolchanger.local/api/change",
+#       "method": "POST",
+#       "timeout": 120,
+#       "block_unpause": true,
+#       "auto_resume": true
+#     },
+#     "program-start": {
+#       "type": "script",
+#       "command": "/usr/local/bin/dust-collector on",
+#       "block_unpause": false
+#     }
+#   }
+#
+#   block_unpause: if true, unpause is blocked until hook completes
+#   auto_resume:   if true AND block_unpause, auto-unpause after hook done
+#
+################################################################################
+
+import os
+import json
+import subprocess
+import threading
+import traceback
+from urllib.request import Request, urlopen
+from urllib.error import URLError
+
+
+# Events that can be hooked
+HOOK_EVENTS = [
+    'tool-change',      # M6 - tool change requested
+    'program-start',    # Program begins running
+    'program-end',      # M2/M30 - program ends
+    'pause',            # M0/M1 - program pause
+    'estop',            # Emergency stop triggered
+    'homing-start',     # Homing cycle begins
+    'homing-end',       # Homing cycle completes
+    'custom',           # Triggered by (MSG,HOOK:name:data) comments
+]
+
+
+class Hooks:
+    def __init__(self, ctrl):
+        self.ctrl = ctrl
+        self.log = ctrl.log.get('Hooks')
+        self.hooks = {}
+
+        # Hook execution state
+        self._hook_busy = False        # True while a blocking hook runs
+        self._hook_busy_event = None   # Which event is blocking
+        self._hook_error = None        # Error from last hook, if any
+        self._hook_thread = None
+
+        # In-process hook handlers registered by Python modules. Keyed by
+        # event name (matches what the G-code emits as HOOK:<event>).
+        # Take precedence over hooks.json entries with the same name.
+        self._internal = {}
+
+        # Track state for edge detection — must be set before add_listener
+        # because add_listener fires immediately with current state
+        self._last_cycle = ctrl.state.get('cycle', 'idle')
+        self._last_state = ctrl.state.get('xx', '')
+        self._last_tool = ctrl.state.get('tool', 0)
+        self._last_pause_reason = ctrl.state.get('pr', '')
+        # Highest message id we've already inspected for HOOK: lines.
+        self._last_msg_id = -1
+        self._initialized = False
+
+        self._load_config()
+
+        # Listen for state changes
+        ctrl.state.add_listener(self._on_state_change)
+        self._initialized = True
+
+    # -- Config management --
+
+    def _get_config_path(self):
+        return self.ctrl.get_path(filename='hooks.json')
+
+    def _load_config(self):
+        path = self._get_config_path()
+        if os.path.exists(path):
+            try:
+                with open(path) as f:
+                    self.hooks = json.load(f)
+                self.log.info('Loaded %d hook(s) from %s' %
+                              (len(self.hooks), path))
+            except Exception:
+                self.log.error('Failed to load hooks.json: %s' %
+                               traceback.format_exc())
+        else:
+            self.log.info('No hooks.json found, hooks disabled')
+
+    def save_config(self, config):
+        """Save hook configuration (called from API)."""
+        path = self._get_config_path()
+        with open(path, 'w') as f:
+            json.dump(config, f, indent=2)
+        self.hooks = config
+        self.log.info('Saved %d hook(s)' % len(config))
+
+    def get_config(self):
+        return self.hooks
+
+    # -- Unpause gating (called from Mach) --
+
+    def can_unpause(self):
+        """Returns True if no blocking hook is running.
+        Called by Mach.unpause() to gate resume."""
+        if self._hook_busy:
+            self.log.info('Unpause blocked: hook "%s" still running' %
+                          self._hook_busy_event)
+            return False
+        return True
+
+    def get_status(self):
+        """Return current hook execution status for the UI."""
+        return {
+            'busy': self._hook_busy,
+            'event': self._hook_busy_event,
+            'error': self._hook_error,
+        }
+
+    # -- State change listener --
+
+    def _on_state_change(self, update):
+        """Called on every state update from the controller."""
+        if not self._initialized:
+            return
+        state = self.ctrl.state
+
+        # Detect tool change (tool number changed while HOLDING)
+        if 'tool' in update:
+            new_tool = update['tool']
+            if new_tool != self._last_tool:
+                self._fire('tool-change', {
+                    'old_tool': self._last_tool,
+                    'new_tool': new_tool,
+                })
+                self._last_tool = new_tool
+
+        # Detect cycle changes
+        if 'cycle' in update:
+            new_cycle = update['cycle']
+            if new_cycle != self._last_cycle:
+                if new_cycle == 'running' and self._last_cycle == 'idle':
+                    self._fire('program-start', {})
+                elif new_cycle == 'idle' and self._last_cycle == 'running':
+                    self._fire('program-end', {})
+                elif new_cycle == 'homing':
+                    self._fire('homing-start', {})
+                elif self._last_cycle == 'homing' and new_cycle == 'idle':
+                    self._fire('homing-end', {})
+                self._last_cycle = new_cycle
+
+        # Detect AVR state changes
+        if 'xc' in update or 'xx' in update:
+            new_state = state.get('xx', '')
+            if new_state != self._last_state:
+                if new_state == 'ESTOPPED':
+                    # Cancel any running hook on estop. The hook thread
+                    # cannot be killed from Python, but we can ask the
+                    # AuxAxis to send ABORT to the ESP so its in-flight
+                    # motion stops. Also drain the external-axis
+                    # worker queue so resume after clear doesn't replay
+                    # stale moves.
+                    try:
+                        ext = getattr(self.ctrl, 'ext_axis', None)
+                        if ext is not None:
+                            ext.abort()
+                    except Exception:
+                        pass
+                    if self._hook_busy:
+                        self.log.warning('E-stop: cancelling hook "%s"' %
+                                         self._hook_busy_event)
+                        try:
+                            aux = getattr(self.ctrl, 'aux', None)
+                            if aux is not None:
+                                aux.abort()
+                        except Exception:
+                            pass
+                        self._hook_busy = False
+                        self._hook_busy_event = None
+                    self._fire('estop', {})
+                self._last_state = new_state
+
+        # Detect pause
+        if 'pr' in update:
+            pr = update['pr']
+            if pr and pr != self._last_pause_reason:
+                self._fire('pause', {'reason': pr})
+            self._last_pause_reason = pr
+
+        # Detect custom hook messages emitted via (MSG,HOOK:event_name:data)
+        # gcode comments. State stores them as a list under 'messages'
+        # ([{'id': N, 'text': '...'}, ...]); fire only on new ids.
+        if 'messages' in update:
+            msgs = update['messages']
+            if isinstance(msgs, list):
+                for m in msgs:
+                    try:
+                        mid = m.get('id', -1)
+                        text = m.get('text', '')
+                    except AttributeError:
+                        continue
+                    if mid <= self._last_msg_id:
+                        continue
+                    self._last_msg_id = mid
+                    if isinstance(text, str) and text.startswith('HOOK:'):
+                        parts = text[5:].split(':', 1)
+                        event = parts[0]
+                        data = parts[1] if len(parts) > 1 else ''
+                        self._fire('custom', {
+                            'event': event,
+                            'data': data,
+                        }, custom_name=event)
+
+    # -- Hook execution --
+
+    def dispatch_hook_message(self, text):
+        """Direct entry point for HOOK:<event>:<data> messages emitted
+        by the planner via (MSG,HOOK:...) comments. Bypasses the
+        state.messages list (which the UI also reads), so callers can
+        suppress popup display without losing the hook dispatch.
+
+        Returns True if the text matched a HOOK: line and was
+        dispatched, False otherwise."""
+        if not isinstance(text, str) or not text.startswith('HOOK:'):
+            return False
+        parts = text[5:].split(':', 1)
+        event = parts[0]
+        data = parts[1] if len(parts) > 1 else ''
+        self._fire('custom', {'event': event, 'data': data},
+                   custom_name=event)
+        return True
+
+    def register_internal(self, name, fn, block_unpause=True,
+                          auto_resume=True, timeout=120):
+        """Register an in-process handler for HOOK:<name> events.
+
+        fn(context) -> None. May raise. Runs synchronously in the hook
+        thread; while it runs and block_unpause=True, Mach.unpause is
+        gated."""
+        self._internal[name] = {
+            'type': 'internal',
+            'fn': fn,
+            'block_unpause': block_unpause,
+            'auto_resume': auto_resume,
+            'timeout': timeout,
+        }
+        self.log.info('Registered internal hook: %s' % name)
+
+    def _fire(self, event, context, custom_name=None):
+        """Fire a hook event."""
+        # Internal handlers win over hooks.json entries.
+        hook = None
+        if custom_name:
+            hook = self._internal.get(custom_name)
+        if not hook:
+            hook = self._internal.get(event)
+        if not hook:
+            hook = self.hooks.get(event)
+            if custom_name and not hook:
+                hook = self.hooks.get(custom_name)
+        if not hook:
+            return
+
+        self.log.info('Hook firing: %s %s' % (event, json.dumps(context)))
+
+        # Add standard context
+        state = self.ctrl.state
+        context.update({
+            'event': event,
+            'position': (state.get_position()
+                         if hasattr(state, 'get_position') else {}),
+            'state': state.get('xx', ''),
+            'cycle': state.get('cycle', 'idle'),
+        })
+
+        block_unpause = hook.get('block_unpause', event == 'tool-change')
+        auto_resume = hook.get('auto_resume', False)
+
+        if block_unpause:
+            # Run in thread, block unpause until done
+            self._hook_busy = True
+            self._hook_busy_event = event
+            self._hook_error = None
+
+            # Update UI state so frontend knows we're busy
+            self.ctrl.state.set('hook_busy', True)
+            self.ctrl.state.set('hook_event', event)
+
+            self._hook_thread = threading.Thread(
+                target=self._run_hook_blocking,
+                args=(hook, event, context, auto_resume),
+                daemon=True
+            )
+            self._hook_thread.start()
+        else:
+            # Fire and forget (non-blocking)
+            self._execute_hook(hook, context)
+
+    def _run_hook_blocking(self, hook, event, context, auto_resume):
+        """Runs in a background thread. Blocks unpause until complete."""
+        try:
+            self._execute_hook(hook, context)
+            self.log.info('Hook "%s" completed successfully' % event)
+        except Exception as e:
+            self._hook_error = str(e)
+            self.log.error('Hook "%s" failed: %s' % (event, e))
+        finally:
+            self._hook_busy = False
+            self._hook_busy_event = None
+
+            # Schedule UI update on the ioloop thread
+            self.ctrl.ioloop.call_later(0, self._hook_finished, auto_resume)
+
+    def _hook_finished(self, auto_resume):
+        """Called on the ioloop after a blocking hook completes."""
+        self.ctrl.state.set('hook_busy', False)
+        self.ctrl.state.set('hook_event', '')
+
+        if self._hook_error:
+            self.ctrl.state.set('hook_error', self._hook_error)
+            self.log.error('Hook error: %s' % self._hook_error)
+        else:
+            self.ctrl.state.set('hook_error', '')
+
+        if auto_resume and not self._hook_error:
+            self.log.info('Hook done, auto-resuming')
+            try:
+                self.ctrl.mach.unpause()
+            except Exception as e:
+                self.log.error('Auto-resume failed: %s' % e)
+
+    def _execute_hook(self, hook, context):
+        """Execute a single hook (webhook, script, or internal). May block."""
+        hook_type = hook.get('type', 'webhook')
+
+        if hook_type == 'webhook':
+            self._fire_webhook(hook, context)
+        elif hook_type == 'script':
+            self._fire_script(hook, context)
+        elif hook_type == 'internal':
+            fn = hook.get('fn')
+            if fn is None:
+                raise Exception('Internal hook missing fn')
+            fn(context)
+        else:
+            raise Exception('Unknown hook type: %s' % hook_type)
+
+    def _fire_webhook(self, hook, context):
+        """Fire a webhook HTTP request."""
+        url = hook.get('url')
+        if not url:
+            raise Exception('Webhook missing url')
+
+        method = hook.get('method', 'POST').upper()
+        timeout = hook.get('timeout', 30)
+        headers = dict(hook.get('headers', {}))
+        body = dict(hook.get('body', {}))
+
+        # Merge context into body
+        body['_context'] = context
+
+        data = json.dumps(body).encode('utf-8')
+        headers['Content-Type'] = 'application/json'
+
+        req = Request(url, data=data, headers=headers, method=method)
+        self.log.info('Webhook %s %s' % (method, url))
+
+        resp = urlopen(req, timeout=timeout)
+        self.log.info('Webhook response: %d' % resp.status)
+
+        if resp.status >= 400:
+            raise Exception('Webhook returned %d' % resp.status)
+
+    def _fire_script(self, hook, context):
+        """Fire a local script/command. Blocks until complete."""
+        command = hook.get('command')
+        if not command:
+            raise Exception('Script hook missing command')
+
+        timeout = hook.get('timeout', 120)
+
+        # Pass context as environment variables
+        env = os.environ.copy()
+        env['HOOK_EVENT'] = context.get('event', '')
+        env['HOOK_STATE'] = context.get('state', '')
+        env['HOOK_CYCLE'] = context.get('cycle', '')
+        env['HOOK_DATA'] = json.dumps(context)
+
+        if 'old_tool' in context:
+            env['HOOK_OLD_TOOL'] = str(context['old_tool'])
+        if 'new_tool' in context:
+            env['HOOK_NEW_TOOL'] = str(context['new_tool'])
+
+        self.log.info('Script: %s' % command)
+
+        result = subprocess.run(
+            command, shell=True, env=env,
+            timeout=timeout,
+            stdout=subprocess.PIPE, stderr=subprocess.PIPE
+        )
+
+        stdout = result.stdout.decode('utf-8', errors='replace').strip()
+        stderr = result.stderr.decode('utf-8', errors='replace').strip()
+
+        if stdout:
+            self.log.info('Script stdout: %s' % stdout)
+
+        if result.returncode != 0:
+            raise Exception('Script failed (%d): %s' %
+                            (result.returncode, stderr or 'non-zero exit'))

src/py/bbctrl/Log.py

@@ -182,4 +182,11 @@ class Log(object):
             if n == 16: os.unlink(fullpath)
             else: self._rotate(path, nextN)
 
-            os.rename(fullpath, '%s.%d' % (path, nextN))
+            # The recursive call may have unlinked or rotated this
+            # path; tolerate a missing source rather than crashing
+            # bbctrl on startup. This also tolerates concurrent
+            # logrotate runs from /etc/cron.reboot.
+            try:
+                os.rename(fullpath, '%s.%d' % (path, nextN))
+            except FileNotFoundError:
+                pass

src/py/bbctrl/Mach.py

@@ -95,6 +95,10 @@ class Mach(Comm):
         self.planner = bbctrl.Planner(ctrl)
         self.unpausing = False
         self.stopping = False
+        # Guard against overlapping deferred-external-homing threads
+        # if the user clicks Home (All) again while the previous run
+        # is still waiting for the AVR cycle to finish.
+        self._ext_home_thread = None
 
         ctrl.state.set('cycle', 'idle')
 
@@ -256,6 +260,12 @@ class Mach(Comm):
             if   cmd[0] == '$':  self._query_var(cmd)
             elif cmd[0] == '\\': super().queue_command(cmd[1:])
             else:
+                # Rewrite ATC M-codes in MDI input the same way the
+                # FileHandler rewrites uploaded files. Motion (X/Y/Z/A)
+                # is left unchanged: the planner handles it natively
+                # now that the auxcnc stepper is exposed as a virtual
+                # A axis (see ExternalAxis).
+                cmd = self._rewrite_aux_mdi(cmd)
                 self._begin_cycle('mdi')
                 self.planner.mdi(cmd, with_limits)
                 super().resume()
@@ -263,11 +273,51 @@ class Mach(Comm):
             self.mlog.info("Exception during MDI: %s" % err)
             pass
 
+    def _rewrite_aux_mdi(self, cmd):
+        """Apply the ATC M-code preprocessor to a single MDI line.
+        Returns possibly-multi-line G-code with HOOK: comments inserted."""
+        try:
+            from bbctrl.AuxPreprocessor import AuxPreprocessor, _ATC_M_RE
+            if not _ATC_M_RE.search(cmd):
+                return cmd
+            import io, tempfile, os
+            # AuxPreprocessor.process is file-based; route through
+            # tempfiles so we don't fork the regex/state logic.
+            pre = AuxPreprocessor(log=self.mlog)
+            with tempfile.NamedTemporaryFile('w', suffix='.nc',
+                                              delete=False) as fi:
+                fi.write(cmd if cmd.endswith('\n') else cmd + '\n')
+                ipath = fi.name
+            opath = ipath + '.out'
+            try:
+                pre.process(ipath, opath)
+                rewritten = open(opath).read()
+            finally:
+                try: os.unlink(ipath)
+                except OSError: pass
+                try: os.unlink(opath)
+                except OSError: pass
+            return rewritten
+        except Exception as e:
+            self.mlog.warning('Aux MDI rewrite failed: %s' % e)
+            return cmd
+
     def set(self, code, value):
         super().queue_command('${}={}'.format(code, value))
 
 
     def jog(self, axes):
+        # Strip the external axis from the jog request before sending
+        # to the AVR. v1 doesn't support continuous-rate jogging on
+        # the ESP-driven axis - users jog A via /api/aux/jog (relative
+        # mm steps) instead. Sending A to the AVR is harmless (no
+        # motor maps to it) but cleaner to strip.
+        ext = getattr(self.ctrl, 'ext_axis', None)
+        if ext is not None and isinstance(axes, dict):
+            axes = {k: v for k, v in axes.items()
+                    if k.lower() != ext.axis_letter}
+            if not axes:
+                return
         self._begin_cycle('jogging')
         self.planner.position_change()
         super().queue_command(Cmd.jog(axes))
@@ -281,10 +331,52 @@ class Mach(Comm):
             axes = 'zxybc' if is_rotary_active else 'zxyabc' # TODO This should be configurable
         else: axes = '%c' % axis
 
+        # Collect external axes here and process them *after* every
+        # AVR axis above has finished its homing cycle. Without this,
+        # the AVR is still running Z/X/Y homing G-code in the
+        # planner queue while ext.home() synchronously drives the ESP
+        # to home A in parallel - which is unsafe (the gantry and W
+        # axis can move at the same time) and visually confusing.
+        # We defer external homing to a background thread that
+        # polls cycle until the AVR cycle completes.
+        external_pending = []
+
         for axis in axes:
             enabled = state.is_axis_enabled(axis)
             mode = state.axis_homing_mode(axis)
 
+            # External axes (e.g. the auxcnc-driven A axis) home via
+            # their own ESP-side homing routine; the standard
+            # G28.2 / G38.6 / latch sequence doesn't apply.
+            #
+            # After homing we want a deterministic outcome regardless
+            # of where the user was before:
+            #   physical position = home_position_mm   (e.g. 134 mm)
+            #   work-coord origin = home position      (user A = 0)
+            #   work offset       = home_position_mm   (so abs - off = 0)
+            #
+            # ext.home() blocks on the ESP and updates state.ap to
+            # home_position_mm. We then need to tell the AVR (so its
+            # ex.position[A] matches physical reality) and gplan
+            # (so trajectory planning sees abs at home).
+            #
+            # We deliberately avoid G28.3 here: gplan's G28.3 keeps the
+            # current user-coord position fixed and adjusts the offset
+            # to match the new abs, which means re-homing after a move
+            # accumulates offset (134 -> 268 -> ...). Using G92 a0
+            # *after* syncing abs gives the desired "user A = 0 here"
+            # outcome with offset = home_position every time.
+            ext = getattr(self.ctrl, 'ext_axis', None)
+            if ext is not None and ext.enabled \
+                    and ext.axis_letter == axis.lower():
+                if 1 < len(axes) and not enabled:
+                    continue
+                # Defer until AVR axes are done. We capture the axis
+                # letter and ext reference; the actual homing runs
+                # in _run_external_homing below.
+                external_pending.append((axis, ext))
+                continue
+
             # If this is not a request to home a specific axis and the
             # axis is disabled or in manual homing mode, don't show any
             # warnings
@@ -315,8 +407,138 @@ class Mach(Comm):
             self.planner.mdi(gcode, False)
             super().resume()
 
+        # Kick off the deferred external-axis homing on a background
+        # thread so we don't block the HTTP handler (which is on the
+        # IOLoop) waiting for the AVR cycle to finish.
+        if external_pending:
+            prev = self._ext_home_thread
+            if prev is not None and prev.is_alive():
+                self.mlog.info(
+                    'External homing already in progress; ignoring '
+                    'duplicate request')
+            else:
+                import threading
+                t = threading.Thread(
+                    target=self._run_external_homing,
+                    args=(list(external_pending),),
+                    name='ext-home-deferred',
+                    daemon=True)
+                self._ext_home_thread = t
+                t.start()
 
-    def unhome(self, axis): self.mdi('G28.2 %c0' % axis)
+    def _run_external_homing(self, pending):
+        """Background worker: wait for the AVR cycle to drop to idle
+        (meaning all queued AVR-side homing is done), then run each
+        deferred external-axis home in order.
+
+        We split the work between two threads:
+          - this background thread blocks on the ESP serial RPC
+            (ext.home(), which can take 5-10 seconds while the
+            carriage seeks the limit and backs off twice);
+          - small bookkeeping operations that touch gplan, the AVR
+            command queue, or shared State are scheduled back onto
+            the IOLoop via ctrl.ioloop.add_callback() so we don't
+            race with the rest of the controller.
+        """
+        import time
+        # Wait up to 5 minutes for the AVR cycle to leave 'homing'.
+        # Long enough for any reasonable Onefinity full-travel home
+        # (Y axis at slow rate covers ~800 mm).
+        deadline = time.time() + 300.0
+        while time.time() < deadline:
+            cycle = self._get_cycle()
+            # 'homing' is the AVR's homing cycle; we wait for it to
+            # return to idle. If the user estopped or the cycle was
+            # aborted, cycle goes to idle too - we still proceed and
+            # the external home will fail-soft if conditions are wrong.
+            if cycle == 'idle':
+                break
+            time.sleep(0.1)
+        else:
+            self.mlog.error(
+                'External axis homing aborted: AVR cycle did not '
+                'return to idle within timeout')
+            return
+
+        for axis, ext in pending:
+            self.mlog.info('Homing external %s axis via auxcnc' %
+                           axis.upper())
+            # Begin the cycle on the IOLoop so cycle-state writes go
+            # through the same thread that all other state writes do.
+            self.ctrl.ioloop.add_callback(self._begin_cycle, 'homing')
+            try:
+                # ext.home() runs on this background thread - it
+                # blocks on serial I/O and is fully thread-safe (the
+                # AuxAxis driver has its own RPC lock).
+                ext.home()
+                home_mm = ext.home_position_mm
+                # All of the post-home bookkeeping touches gplan and
+                # the AVR command queue, both of which run on the
+                # IOLoop. Schedule it there in a single callback so
+                # the steps run in order without intervening events.
+                self.ctrl.ioloop.add_callback(
+                    self._finish_external_home, axis, home_mm)
+            except Exception as e:
+                self.mlog.error(
+                    'External axis homing failed: %s' % e)
+                # Cycle reset must also happen on the IOLoop. Without
+                # this the UI stays locked at 'homing' since the AVR
+                # never moved (no state change to drive _update's
+                # cycle-end path).
+                self.ctrl.ioloop.add_callback(
+                    self._abort_external_home_cycle)
+
+    def _finish_external_home(self, axis, home_mm):
+        """IOLoop-side completion of an external axis home.
+        Synchronizes AVR position, refreshes the planner, and emits
+        a G92 to set the user-coord origin at the home position.
+        """
+        try:
+            # 1) Update AVR: no motor steps, just position sync.
+            super().queue_command(Cmd.set_axis(axis, home_mm))
+            # 2) Force planner to resync abs from State on the next
+            #    planner call (which is the MDI below).
+            self.planner.position_change()
+            # 3) G92 <axis>0: with abs already at home_mm, sets
+            #    user-coord A = 0 and offset = home_mm. Use
+            #    planner.mdi (not Mach.mdi) so we don't flip cycle
+            #    to 'mdi' inside the 'homing' cycle.
+            self.planner.mdi('G92 %c0' % axis, False)
+            super().resume()
+        except Exception:
+            self.mlog.exception(
+                'Post-home bookkeeping failed for external axis')
+            self._abort_external_home_cycle()
+
+    def _abort_external_home_cycle(self):
+        """Reset cycle to idle from the IOLoop after a failed
+        external axis home. The AVR never moved so _update's normal
+        cycle-end path won't fire; do it explicitly here.
+        """
+        if self._get_cycle() == 'homing':
+            try:
+                self._set_cycle('idle')
+            except Exception:
+                self.mlog.exception(
+                    'Failed to reset cycle to idle after external '
+                    'homing error')
+
+
+    def unhome(self, axis):
+        # External axes don't have AVR-side homed state to clear; the
+        # ESP holds its own homed flag. We don't have an explicit
+        # "unhome" verb on the ESP, but a stale homed flag is harmless
+        # because the next absolute move will fail-soft via
+        # ExternalAxis._pos_mm sync. Still mirror the cleared flag
+        # into State for the UI.
+        ext = getattr(self.ctrl, 'ext_axis', None)
+        if ext is not None and ext.enabled \
+                and chr(axis).lower() == ext.axis_letter:
+            from bbctrl.ExternalAxis import EXTERNAL_MOTOR_INDEX
+            self.ctrl.state.set('%dh' % EXTERNAL_MOTOR_INDEX, 0)
+            self.ctrl.state.set(ext.axis_letter + '_homed', False)
+            return
+        self.mdi('G28.2 %c0' % axis)
     def estop(self): super().estop()
 
 
@@ -343,12 +565,22 @@ class Mach(Comm):
     def stop(self):
         if self._get_state() != 'jogging': self.stopping = True
         super().i2c_command(Cmd.STOP)
+        # Drain the external-axis worker queue so post-stop resumption
+        # doesn't replay queued moves that the user wanted cancelled.
+        ext = getattr(self.ctrl, 'ext_axis', None)
+        if ext is not None:
+            try: ext.abort()
+            except Exception: pass
         
     def pause(self): super().pause()
 
 
     def unpause(self):
         if self._is_paused():
+            # Gate unpause on hook completion
+            if hasattr(self.ctrl, 'hooks') and \
+               not self.ctrl.hooks.can_unpause():
+                return
             self.ctrl.state.set('optional_pause', False)
             self._unpause()
 

src/py/bbctrl/Planner.py

@@ -30,7 +30,22 @@ import math
 import re
 import time
 from collections import deque
-import camotics.gplan as gplan # pylint: disable=no-name-in-module,import-error
+# camotics.gplan is heavy (loads a C++ extension that pulls in libstdc++,
+# boost::python, etc.). Defer it: bbctrl can listen on HTTP and serve
+# the UI without ever touching the planner. Lazy-load the first time
+# Planner.init() runs, which is when the user actually queues motion.
+gplan = None
+def _load_gplan():
+    global gplan
+    if gplan is None:
+        try:
+            import bbctrl.Trace as _T
+            with _T.span('imports.camotics_gplan'):
+                import camotics.gplan as _gplan # pylint: disable=no-name-in-module,import-error
+        except Exception:
+            import camotics.gplan as _gplan # pylint: disable=no-name-in-module,import-error
+        gplan = _gplan
+    return gplan
 import bbctrl.Cmd as Cmd
 from bbctrl.CommandQueue import CommandQueue
 
@@ -181,12 +196,23 @@ class Planner():
 
 
     def _add_message(self, text):
-        self.ctrl.state.add_message(text)
-
         line = self.ctrl.state.get('line', 0)
         if 0 <= line: where = '%s:%d' % (self.where, line)
         else: where = self.where
 
+        # HOOK:<event>:<data> messages are an internal IPC channel
+        # between the gcode preprocessor and Hooks; bypass the user
+        # message list so they don't surface as popups, and dispatch
+        # the hook directly. Routing through state.messages would
+        # only deliver it after the 0.25s state-change debounce, by
+        # which point we'd have to keep it visible to ensure Hooks
+        # could see it.
+        hooks = getattr(self.ctrl, 'hooks', None)
+        if hooks is not None and hooks.dispatch_hook_message(text):
+            self.log.info('HOOK msg: %s' % text, where = where)
+            return
+
+        self.ctrl.state.add_message(text)
         self.log.message(text, where = where)
 
 
@@ -244,6 +270,54 @@ class Planner():
         if type != 'set': self.log.info('Cmd:' + log_json(block))
 
         if type == 'line':
+            # Z-A coupling check: every line block that touches Z (or
+            # A) is validated against the projected (A,Z) machine
+            # pair. The ExternalAxis check is improvement-aware: it
+            # only refuses moves that worsen an existing violation
+            # or push a healthy state into one. So pure-XY jogs and
+            # recovery moves (Z up, A down) are not rejected even
+            # when (A-Z) is currently above the bound.
+            ext_check = getattr(self.ctrl, 'ext_axis', None)
+            if ext_check is not None:
+                from bbctrl.ExternalAxis import ExternalAxisError
+                target = block.get('target') or {}
+                z_target = target.get('z')
+                if z_target is None: z_target = target.get('Z')
+                a_letter = ext_check.axis_letter
+                a_target = target.get(a_letter)
+                if a_target is None:
+                    a_target = target.get(a_letter.upper())
+                if z_target is not None or a_target is not None:
+                    try:
+                        ext_check.check_coupling(
+                            target_a_machine=a_target,
+                            target_z_machine=z_target)
+                    except ExternalAxisError as e:
+                        # Convert the raw error into a clean abort:
+                        # surface the message to the operator, stop
+                        # the cycle, and skip this block. Returning
+                        # None drops the block from the AVR queue;
+                        # mach.stop() halts further planner output
+                        # so the rest of an offending program can't
+                        # leak through. The planner stays usable
+                        # for new MDI / jog commands.
+                        self.log.warning('Z-A coupling refused: %s' % e)
+                        try:
+                            self.ctrl.state.add_message(
+                                'Z-A coupling refused move: ' + str(e))
+                        except Exception: pass
+                        try:
+                            self.ctrl.mach.stop()
+                        except Exception: pass
+                        return None
+
+            ext = self._external_axis_for_line(block)
+            if ext is not None:
+                # Side effect: enqueue the ESP move on the external-
+                # axis worker. The AVR still receives the full target
+                # (including A) so ex.position[A] tracks gplan; no
+                # motor steps for A because no motor maps to it.
+                self._dispatch_external_line(block, ext)
             self._enqueue_line_time(block)
             return Cmd.line(block['target'], block['exit-vel'],
                             block['max-accel'], block['max-jerk'],
@@ -274,8 +348,17 @@ class Planner():
 
                 if name[2:] == '_homed':
                     motor = self.ctrl.state.find_motor(name[1])
-                    if motor is not None:
+                    # Synthetic external motor (index 4) doesn't exist
+                    # on the AVR; mirror the homed flag in State only.
+                    from bbctrl.ExternalAxis import EXTERNAL_MOTOR_INDEX
+                    if motor is not None and motor < EXTERNAL_MOTOR_INDEX:
                         return Cmd.set_sync('%dh' % motor, value)
+                    if motor == EXTERNAL_MOTOR_INDEX:
+                        # Update synthetic motor flag and the<axis>_homed
+                        # projection consumed by the DRO.
+                        self.cmdq.enqueue(
+                            id, self.ctrl.state.set,
+                            '%dh' % EXTERNAL_MOTOR_INDEX, value)
 
             return
 
@@ -324,12 +407,74 @@ class Planner():
             self.planner.set_logger(None)
 
 
+    # ----------------------------------------------- external-axis routing
+    #
+    # When an axis is exposed to gplan via a synthetic motor (no AVR
+    # channel), we need to fork its motion off to the ESP at line
+    # encode time and let the rest of the line proceed to the AVR.
+    # The split is done here rather than in gplan because gplan
+    # treats all six axes uniformly and just emits target dicts; we
+    # don't want to teach it about the ESP.
+
+    def _external_axis_for_line(self, block):
+        """Return the ExternalAxis instance for whichever axis in
+        block['target'] is external, or None."""
+        ext = getattr(self.ctrl, 'ext_axis', None)
+        if ext is None or not ext.enabled:
+            return None
+        target = block.get('target') or {}
+        if ext.axis_letter in target or ext.axis_letter.upper() in target:
+            return ext
+        return None
+
+    def _dispatch_external_line(self, block, ext):
+        """Side-effect: enqueue the ESP move on the external-axis
+        worker thread (non-blocking). Returns the block (possibly
+        unchanged) for the AVR.
+
+        We do NOT strip the external axis target from the AVR line.
+        The AVR's exec_move_to_target updates ex.position[axis] for
+        every axis in the target dict regardless of motor mapping,
+        and reports it back via the `p` indexed var. Leaving A in
+        the target keeps state.ap in sync with gplan's idea of A
+        (otherwise the AVR's stale ex.position[A] would clobber
+        ExternalAxis's state.ap=N update on the next status report).
+
+        The AVR doesn't step any motor for the external axis (no
+        motor maps to it) - so leaving A in the target is
+        physically a no-op for the steppers, while keeping the
+        host-side state coherent.
+
+        We pass the full S-curve parameters to the ESP so its move
+        duration matches the AVR's exactly. The ESP runs the same
+        7-segment jerk-limited trajectory the AVR would have run
+        if A had been a real motor."""
+        target = block.get('target') or {}
+        # Read the external target (case-insensitive) without modifying
+        # the dict so the AVR still sees A.
+        ext_mm = target.get(ext.axis_letter)
+        if ext_mm is None:
+            ext_mm = target.get(ext.axis_letter.upper())
+        try:
+            ext.enqueue_line(
+                ext_mm,
+                block.get('max-accel', 0.0),
+                block.get('max-jerk',  0.0),
+                block.get('entry-vel', 0.0),
+                block.get('exit-vel',  0.0),
+                block.get('times',     [0]*7),
+            )
+        except Exception as e:
+            self.log.error('External axis enqueue failed: %s' % e)
+            raise
+        return block
+
     def reset(self, *args, **kwargs):
         stop = kwargs.get('stop', True)
         if stop:
             self.ctrl.mach.stop()
 
-        self.planner = gplan.Planner()
+        self.planner = _load_gplan().Planner()
         self.planner.set_resolver(self._get_var_cb)
         # TODO logger is global and will not work correctly in demo mode
         self.planner.set_logger(self._log_cb, 1, 'LinePlanner:3')
@@ -337,6 +482,16 @@ class Planner():
         self.cmdq.clear()
         self.reset_times()
 
+        # Drain the external-axis worker queue and force the next
+        # move to re-sync position from the ESP (since State.reset
+        # below will zero <axis>p which makes ext._pos_mm stale).
+        ext = getattr(self.ctrl, 'ext_axis', None)
+        if ext is not None:
+            try: ext.abort()
+            except Exception: pass
+            try: ext._pos_mm = None
+            except Exception: pass
+
         resetState = kwargs.get('resetState', True)
         if resetState:
             self.ctrl.state.reset()
@@ -354,6 +509,22 @@ class Planner():
         self.where = path
         path = self.ctrl.get_path('upload', path)
         self.log.info('GCode:' + path)
+        # Rewrite ATC M-codes (M100..M103) before gplan sees them.
+        # preprocess_file is a no-op when no rewriting is needed and
+        # idempotent when run twice on the same file, so this is
+        # safe on every load. W tokens are no longer rewritten - the
+        # auxcnc stepper is now exposed as a virtual A axis and gcode
+        # should use A directly.
+        try:
+            from bbctrl.AuxPreprocessor import preprocess_file
+            ext = getattr(self.ctrl, 'ext_axis', None)
+            coupling = (ext.coupling_for_preprocessor()
+                        if ext is not None else None)
+            if preprocess_file(path, log=self.log, coupling=coupling):
+                self.log.info('Rewrote (ATC / Z-A coupling) in %s' % path)
+        except Exception:
+            self.log.exception('Aux preprocess at load failed; '
+                               'attempting to load file unchanged')
         self._sync_position()
         self.planner.load(path, self.get_config(False, True))
         self.reset_times()

src/py/bbctrl/State.py

@@ -107,8 +107,14 @@ class State(object):
 
 
     def reset(self):
-        # Unhome all motors
-        for i in range(4): self.set('%dhomed' % i, False)
+        # Unhome all motors (real AVR motors 0..3 and the synthetic
+        # external-axis motor at index 4 used by ExternalAxis).
+        # Both <motor>homed and <motor>h are cleared - they're set
+        # by different code paths (gplan emits homed via _<axis>_homed
+        # set blocks, AVR reports h directly).
+        for i in range(5):
+            self.set('%dhomed' % i, False)
+            self.set('%dh' % i, 0)
 
         # Zero offsets and positions
         for axis in 'xyzabc':
@@ -280,8 +286,11 @@ class State(object):
         axis_motors = {axis: self.find_motor(axis) for axis in 'xyzabc'}
         axis_vars = {}
 
+        # NOTE: motor index '4' is a host-only synthetic motor used
+        # by ExternalAxis to expose the auxcnc ESP-driven stepper as
+        # an additional axis. Real AVR motors are 0..3.
         for name, value in vars.items():
-            if name[0] in '0123':
+            if name[0] in '01234':
                 motor = int(name[0])
 
                 for axis in 'xyzabc':
@@ -330,6 +339,9 @@ class State(object):
     def get_axis_vector(self, name, scale = 1):
         v = {}
 
+        # 0..3 are AVR motor channels. 4 is the host-side synthetic
+        # motor used by ExternalAxis. find_motor returns the right
+        # index regardless of whether the axis is physical or external.
         for axis in 'xyzabc':
             motor = self.find_motor(axis)
 
@@ -351,7 +363,10 @@ class State(object):
 
 
     def find_motor(self, axis):
-        for motor in range(4):
+        # Walk 0..4: 0..3 are real AVR motors, 4 is the synthetic
+        # host-side motor used to expose the auxcnc ESP stepper as
+        # an external axis.
+        for motor in range(5):
             if not ('%dan' % motor) in self.vars: continue
             motor_axis = 'xyzabc'[self.vars['%dan' % motor]]
             if motor_axis == axis.lower() and self.vars.get('%dme' % motor, 0):

src/py/bbctrl/Trace.py

@@ -0,0 +1,185 @@
+################################################################################
+#                                                                              #
+#  Lightweight phase tracing for bbctrl restart / boot timing.                 #
+#                                                                              #
+#  Anchored at module import time. All timestamps are seconds since the        #
+#  process anchor (monotonic). A wall-clock anchor is captured once so the     #
+#  timeline can be aligned with journalctl / systemd-analyze.                  #
+#                                                                              #
+#  Set BBCTRL_TRACE=0 in the environment to disable all marks (no-op).         #
+#                                                                              #
+#  Exposed by /api/diag/timing as JSON.                                        #
+#                                                                              #
+################################################################################
+"""Bbctrl restart / startup tracing.
+
+Usage:
+    import bbctrl.Trace as T
+    T.mark('proc.start')
+    with T.span('ctrl.avr.init'):
+        ...
+
+The timeline is also dumped on demand via /api/diag/timing.
+"""
+
+import os
+import time
+import json
+import threading
+
+
+_ENABLED = os.environ.get('BBCTRL_TRACE', '1') != '0'
+
+_t0_monotonic = time.monotonic()
+_t0_wall = time.time()
+_lock = threading.Lock()
+_events = []        # list of dicts: {t, name, fields}
+_ui_timing = None   # last timeline POSTed by the browser
+
+
+def _read_kernel_anchors():
+    """Return (btime_wall, uptime_at_anchor) so we can express bbctrl events
+    in seconds since kernel boot.
+
+    btime_wall: wall-clock epoch seconds when the kernel booted (from
+    /proc/stat 'btime').
+    uptime_at_anchor: monotonic offset (seconds since kernel boot) at the
+    moment Trace was imported. Equivalent to (Trace anchor) - btime
+    in wall time, but read directly from /proc/uptime so it isn't
+    sensitive to wall-clock skew.
+    """
+    btime = None
+    uptime_at_anchor = None
+    try:
+        with open('/proc/stat') as f:
+            for line in f:
+                if line.startswith('btime '):
+                    btime = int(line.split()[1])
+                    break
+    except Exception:
+        pass
+    try:
+        with open('/proc/uptime') as f:
+            uptime_at_anchor = float(f.read().split()[0])
+    except Exception:
+        pass
+    return btime, uptime_at_anchor
+
+
+_btime_wall, _uptime_at_anchor = _read_kernel_anchors()
+
+
+def now():
+    return time.monotonic() - _t0_monotonic
+
+
+def mark(name, **fields):
+    """Record a single named event at the current monotonic time."""
+    if not _ENABLED:
+        return
+    t = now()
+    ev = {'t': round(t, 4), 'name': name}
+    if fields:
+        ev['fields'] = fields
+    with _lock:
+        _events.append(ev)
+    # Also surface in the regular log stream so journalctl shows it.
+    try:
+        extras = ''
+        if fields:
+            extras = ' ' + ' '.join('%s=%s' % (k, v) for k, v in fields.items())
+        print('TRACE +%.3fs %s%s' % (t, name, extras), flush=True)
+    except Exception:
+        pass
+
+
+class span(object):
+    """Context manager that emits <name>.start / <name>.end with duration."""
+
+    def __init__(self, name, **fields):
+        self.name = name
+        self.fields = fields
+        self._t = None
+
+    def __enter__(self):
+        if _ENABLED:
+            self._t = time.monotonic()
+            mark(self.name + '.start', **self.fields)
+        return self
+
+    def __exit__(self, exc_type, exc, tb):
+        if _ENABLED and self._t is not None:
+            dur_ms = int((time.monotonic() - self._t) * 1000)
+            extra = dict(self.fields)
+            extra['dur_ms'] = dur_ms
+            if exc_type is not None:
+                extra['error'] = exc_type.__name__
+            mark(self.name + '.end', **extra)
+        return False
+
+
+def set_ui_timing(data):
+    global _ui_timing
+    _ui_timing = data
+
+
+def _current_uptime():
+    try:
+        with open('/proc/uptime') as f:
+            return float(f.read().split()[0])
+    except Exception:
+        return None
+
+
+def timeline():
+    with _lock:
+        events = list(_events)
+    return {
+        'enabled': _ENABLED,
+        't0_wall': _t0_wall,
+        't0_iso': time.strftime('%Y-%m-%dT%H:%M:%S', time.localtime(_t0_wall)),
+        'now': now(),
+        'pid': os.getpid(),
+        'events': events,
+        'ui': _ui_timing,
+        # Kernel-boot anchors so the timeline can be expressed in
+        # "seconds since power on".
+        'btime_wall': _btime_wall,
+        'uptime_at_anchor': _uptime_at_anchor,
+        'uptime_now': _current_uptime(),
+    }
+
+
+def dump(path):
+    try:
+        with open(path, 'w') as f:
+            json.dump(timeline(), f, indent=2)
+    except Exception:
+        pass
+
+
+# Sd_notify helper -------------------------------------------------------------
+#
+# Allows bbctrl to tell systemd "I am ready" / "current status is X" so
+# `systemctl status bbctrl` and `systemd-analyze critical-chain` reflect the
+# actual application state instead of just exec start.
+def sd_notify(state):
+    """Send a status line to systemd. Safe no-op when not under systemd."""
+    addr = os.environ.get('NOTIFY_SOCKET')
+    if not addr:
+        return
+    try:
+        import socket
+        sock = socket.socket(socket.AF_UNIX, socket.SOCK_DGRAM)
+        try:
+            # Abstract socket if it starts with '@'
+            target = '\0' + addr[1:] if addr.startswith('@') else addr
+            sock.sendto(state.encode('utf-8'), target)
+        finally:
+            sock.close()
+    except Exception:
+        pass
+
+
+# Mark module-import time so even importing bbctrl shows up.
+mark('trace.import')

src/py/bbctrl/Web.py

@@ -766,6 +766,111 @@ class RotaryHandler(bbctrl.APIHandler):
             log.error('Unexpected error: {}'.format(e))
 
 
+class HooksGetHandler(bbctrl.APIHandler):
+    def get(self):
+        self.write_json(self.get_ctrl().hooks.get_config())
+
+
+class HooksSaveHandler(bbctrl.APIHandler):
+    def put_ok(self):
+        self.get_ctrl().hooks.save_config(self.json)
+
+
+class HooksStatusHandler(bbctrl.APIHandler):
+    def get(self):
+        self.write_json(self.get_ctrl().hooks.get_status())
+
+
+class HooksFireHandler(bbctrl.APIHandler):
+    def put_ok(self, event):
+        data = self.json if hasattr(self, 'json') and self.json else {}
+        self.get_ctrl().hooks._fire(event, data)
+
+
+# ----- W axis (auxcnc) endpoints --------------------------------------------
+
+class AuxConfigGetHandler(bbctrl.APIHandler):
+    def get(self):
+        self.write_json(self.get_ctrl().aux.get_config())
+
+
+class AuxConfigSaveHandler(bbctrl.APIHandler):
+    def put_ok(self):
+        self.get_ctrl().aux.save_config(self.json or {})
+
+
+class AuxStatusHandler(bbctrl.APIHandler):
+    def get(self):
+        aux = self.get_ctrl().aux
+        self.write_json({
+            'enabled':  aux.enabled,
+            'present':  aux.present,
+            'homed':    aux.homed,
+            'pos_mm':   aux.position_mm,
+        })
+
+
+class AuxHomeHandler(bbctrl.APIHandler):
+    def put_ok(self):
+        # Run synchronously. Route through ExternalAxis so the
+        # synthetic motor's homed flag and DRO update.
+        ext = getattr(self.get_ctrl(), 'ext_axis', None)
+        if ext is not None and ext.enabled:
+            ext.home()
+        else:
+            self.get_ctrl().aux.home()
+
+
+class AuxAbortHandler(bbctrl.APIHandler):
+    def put_ok(self):
+        self.get_ctrl().aux.abort()
+
+
+class AuxJogHandler(bbctrl.APIHandler):
+    """Body: {"mm": 1.5}  for relative-mm move,
+             {"steps": 200} for raw step move (bypasses soft limits).
+
+    Note: with the gplan-integrated W axis, jog-by-mm goes through
+    ExternalAxis so the DRO updates and gplan's idea of A's position
+    stays in sync. jog-by-steps still bypasses everything for the
+    homing/setup workflow where the axis isn't homed yet."""
+    def put_ok(self):
+        body = self.json or {}
+        aux = self.get_ctrl().aux
+        ext = getattr(self.get_ctrl(), 'ext_axis', None)
+        if 'mm' in body:
+            delta_mm = float(body['mm'])
+            if ext is not None and ext.enabled and ext._pos_mm is not None:
+                ext.execute_to_mm(ext._pos_mm + delta_mm)
+            else:
+                aux.move_rel_mm(delta_mm)
+        elif 'steps' in body:
+            aux.jog_steps(int(body['steps']))
+        else:
+            raise HTTPError(400, 'mm or steps required')
+
+
+class AuxMoveHandler(bbctrl.APIHandler):
+    """Body: {"mm": 12.5}  absolute move in mm."""
+    def put_ok(self):
+        body = self.json or {}
+        if 'mm' not in body:
+            raise HTTPError(400, 'mm required')
+        ext = getattr(self.get_ctrl(), 'ext_axis', None)
+        if ext is not None and ext.enabled:
+            ext.execute_to_mm(float(body['mm']))
+        else:
+            self.get_ctrl().aux.move_abs_mm(float(body['mm']))
+
+
+class AuxSetZeroHandler(bbctrl.APIHandler):
+    """Body: {"mm": 0}  set current position to <mm>."""
+    def put_ok(self):
+        body = self.json or {}
+        mm = float(body.get('mm', 0.0))
+        self.get_ctrl().aux.set_position_mm(mm)
+
+
 class RemoteDiagnosticsHandler(bbctrl.APIHandler):
 
     def get(self):
@@ -798,6 +903,31 @@ class RemoteDiagnosticsHandler(bbctrl.APIHandler):
                     'message': e.reason or "Unknown"
                 })
 
+class TimingHandler(bbctrl.APIHandler):
+    """Return the bbctrl process startup timeline as JSON.
+
+    Includes monotonic-anchored events from bbctrl.Trace, the wall
+    clock anchor (so the timeline can be aligned with journalctl /
+    systemd-analyze output), and the most recent UI-side timing
+    payload posted by the browser.
+    """
+    def get(self):
+        import bbctrl.Trace as _T
+        self.write_json(_T.timeline())
+
+
+class UITimingHandler(bbctrl.APIHandler):
+    """Browser posts its performance.now() marks here once per load."""
+    def put_ok(self):
+        import bbctrl.Trace as _T
+        # self.json is parsed in APIHandler.prepare()
+        try:
+            _T.set_ui_timing(self.json)
+            _T.mark('ui.posted_timing',
+                    marks=len(self.json.get('marks', []) or []))
+        except Exception: pass
+
+
 # Base class for Web Socket connections
 class ClientConnection(object):
     def __init__(self, app):
@@ -873,6 +1003,12 @@ class SockJSConnection(ClientConnection, sockjs.tornado.SockJSConnection):
             ip = info.ip
             if 'X-Real-IP' in info.headers: ip = info.headers['X-Real-IP']
             self.app.get_ctrl(id).log.get('Web').info('Connection from %s' % ip)
+            try:
+                if not getattr(self.app, '_first_ws', False):
+                    self.app._first_ws = True
+                    import bbctrl.Trace as _T
+                    _T.mark('ws.first_open', ip=ip)
+            except Exception: pass
             super().on_open(id)
 
 
@@ -881,6 +1017,23 @@ class StaticFileHandler(tornado.web.StaticFileHandler):
         self.set_header('Cache-Control',
                         'no-store, no-cache, must-revalidate, max-age=0')
 
+    def prepare(self):
+        # Mark the first request for the index page so we can see when
+        # chromium actually started fetching the UI on cold boot.
+        try:
+            app = self.application
+            if not getattr(app, '_first_root_get', False):
+                # Treat any GET '/' or '/index.html' as the root fetch.
+                p = self.request.path
+                if p in ('/', '/index.html', ''):
+                    app._first_root_get = True
+                    import bbctrl.Trace as _T
+                    _T.mark('web.first_root_get',
+                            ip=self.request.remote_ip,
+                            ua=(self.request.headers.get('User-Agent') or '')[:60])
+        except Exception: pass
+        return super().prepare()
+
 class Web(tornado.web.Application):
     def __init__(self, args, ioloop):
         self.args = args
@@ -902,6 +1055,8 @@ class Web(tornado.web.Application):
 
         handlers = [
             (r'/websocket', WSConnection),
+            (r'/api/diag/timing', TimingHandler),
+            (r'/api/diag/timing/ui', UITimingHandler),
             (r'/api/log', LogHandler),
             (r'/api/message/(\d+)/ack', MessageAckHandler),
             (r'/api/bugreport', BugReportHandler),
@@ -941,6 +1096,18 @@ class Web(tornado.web.Application):
             (r'/api/time', TimeHandler),
             (r'/api/rotary', RotaryHandler),
             (r'/api/remote-diagnostics', RemoteDiagnosticsHandler),
+            (r'/api/hooks', HooksGetHandler),
+            (r'/api/hooks/save', HooksSaveHandler),
+            (r'/api/hooks/status', HooksStatusHandler),
+            (r'/api/hooks/fire/([\w-]+)', HooksFireHandler),
+            (r'/api/aux/config', AuxConfigGetHandler),
+            (r'/api/aux/config/save', AuxConfigSaveHandler),
+            (r'/api/aux/status', AuxStatusHandler),
+            (r'/api/aux/home', AuxHomeHandler),
+            (r'/api/aux/abort', AuxAbortHandler),
+            (r'/api/aux/jog', AuxJogHandler),
+            (r'/api/aux/move', AuxMoveHandler),
+            (r'/api/aux/set-zero', AuxSetZeroHandler),
             (r'/(.*)', StaticFileHandler,
              {'path': bbctrl.get_resource('http/'),
               'default_filename': 'index.html'}),

src/py/bbctrl/__init__.py

@@ -36,6 +36,13 @@ import datetime
 
 from pkg_resources import Requirement, resource_filename
 
+# Trace must be imported before the rest of bbctrl so its monotonic
+# anchor is the earliest reasonable point and so import-time costs of
+# heavy submodules (camotics gplan.so, sockjs, tornado, etc.) are
+# attributable in /api/diag/timing.
+import bbctrl.Trace as Trace
+Trace.mark('imports.bbctrl.start')
+
 from bbctrl.RequestHandler import RequestHandler
 from bbctrl.APIHandler import APIHandler
 from bbctrl.FileHandler import FileHandler
@@ -59,11 +66,16 @@ from bbctrl.AVR import AVR
 from bbctrl.AVREmu import AVREmu
 from bbctrl.IOLoop import IOLoop
 from bbctrl.MonitorTemp import MonitorTemp
+from bbctrl.Hooks import Hooks
+from bbctrl.AuxAxis import AuxAxis
+from bbctrl.ExternalAxis import ExternalAxis
 import bbctrl.Cmd as Cmd
 import bbctrl.v4l2 as v4l2
 import bbctrl.Log as log
 import bbctrl.ObjGraph as ObjGraph
 
+Trace.mark('imports.bbctrl.end')
+
 
 ctrl = None
 
@@ -167,19 +179,28 @@ def parse_args():
 def run():
     global ctrl
 
+    Trace.mark('run.enter')
     args = parse_args()
+    Trace.mark('args.parsed')
 
     # Set signal handler
     signal.signal(signal.SIGTERM, on_exit)
 
     # Create ioloop
     ioloop = tornado.ioloop.IOLoop.current()
+    Trace.mark('ioloop.created')
 
     # Set ObjGraph signal handler
     if args.debug: Debugger(ioloop, args.debug)
 
     # Start server
-    web = Web(args, ioloop)
+    with Trace.span('web.init'):
+        web = Web(args, ioloop)
+    Trace.mark('listen', port=args.port, addr=args.addr)
+
+    # Notify systemd we are ready (no-op when not under systemd).
+    Trace.sd_notify('READY=1\nSTATUS=listening on %s:%d\n' %
+                    (args.addr, args.port))
 
     try:
         ioloop.start()

src/static/css/Audiowide.css

@@ -2,5 +2,5 @@
   font-family: 'Audiowide';
   font-style: normal;
   font-weight: 400;
-  src: local('Audiowide'), local('Audiowide-Regular'), url(http://fonts.gstatic.com/s/audiowide/v4/8XtYtNKEyyZh481XVWfVOqCWcynf_cDxXwCLxiixG1c.ttf) format('truetype');
+  src: local('Audiowide'), local('Audiowide-Regular'), url(https://fonts.gstatic.com/s/audiowide/v4/8XtYtNKEyyZh481XVWfVOqCWcynf_cDxXwCLxiixG1c.ttf) format('truetype');
 }

src/static/js/ui.js

@@ -1,35 +1,37 @@
+// V09 redesign: the legacy side menu was removed. Keep this file
+// shipped in case anything still references it, but no-op the click
+// handler that used to wire up the burger menu so it does not throw
+// "Cannot set properties of null" on the Settings tab.
 (function (window, document) {
+    var menuLink = document.getElementById("menuLink");
+    if (!menuLink) {
+        return;
+    }
 
-    var layout   = document.getElementById('layout'),
-        menu     = document.getElementById('menu'),
-        menuLink = document.getElementById('menuLink');
+    var layout = document.getElementById("layout");
+    var menu   = document.getElementById("menu");
 
     function toggleClass(element, className) {
-        var classes = element.className.split(/\s+/),
-            length = classes.length,
-            i = 0;
-
-        for(; i < length; i++) {
-          if (classes[i] === className) {
-            classes.splice(i, 1);
-            break;
-          }
+        if (!element) return;
+        var classes = element.className.split(/\s+/);
+        var i;
+        for (i = 0; i < classes.length; i++) {
+            if (classes[i] === className) {
+                classes.splice(i, 1);
+                break;
+            }
         }
-        // The className is not found
-        if (length === classes.length) {
+        if (i === classes.length) {
             classes.push(className);
         }
-
-        element.className = classes.join(' ');
+        element.className = classes.join(" ");
     }
 
     menuLink.onclick = function (e) {
-        var active = 'active';
-
+        var active = "active";
         e.preventDefault();
         toggleClass(layout, active);
         toggleClass(menu, active);
         toggleClass(menuLink, active);
     };
-
 }(this, this.document));

src/svelte-components/src/components/AAxisSettings.svelte

@@ -0,0 +1,336 @@
+<script lang="ts">
+    import { onMount } from "svelte";
+    import Button, { Label } from "@smui/button";
+    import * as api from "$lib/api";
+
+    // Mirrors the DEFAULTS in src/py/bbctrl/AuxAxis.py. The "enabled"
+    // flag is read-only here; toggling the auxiliary A axis on/off
+    // is done via aux.json on disk, so adding/removing the hardware
+    // doesn't have a surprise UI that bricks bring-up. Legacy aux.json
+    // files using min_w/max_w are migrated up to min_mm/max_mm by
+    // AuxAxis._migrate_legacy_fields on load.
+    type AuxConfig = {
+        enabled: boolean;
+        port: string;
+        baud: number;
+        steps_per_mm: number;
+        dir_sign: number;
+        axis_letter: string;
+        min_mm: number;
+        max_mm: number;
+        max_feed_mm_min: number;
+        max_velocity_m_per_min: number;
+        max_accel_km_per_min2: number;
+        max_jerk_km_per_min3: number;
+        home_dir: string;
+        home_position_mm: number;
+        home_fast_sps: number;
+        home_slow_sps: number;
+        home_backoff_steps: number;
+        home_maxtravel_steps: number;
+        step_max_sps: number;
+        step_accel_sps2: number;
+        step_start_sps: number;
+        limit_low: boolean;
+        couple_z_enabled: boolean;
+        couple_z_clearance_mm: number;
+        z_home_mm: number;
+    };
+
+    let cfg: AuxConfig | null = null;
+    let status: { enabled: boolean; present: boolean; homed: boolean; pos_mm: number } | null = null;
+    let busy = false;
+
+    // Listen for the global "save-all" event the Vue root dispatches
+    // when the user clicks the master Save button. We persist our
+    // current cfg the same way the in-form button used to. This way
+    // the user only ever needs one Save button.
+    function onGlobalSave() {
+        save().catch(e => console.error("aux save failed:", e));
+    }
+
+    onMount(async () => {
+        await refresh();
+        window.addEventListener("onefin:save-all", onGlobalSave);
+        return () => window.removeEventListener("onefin:save-all", onGlobalSave);
+    });
+
+    async function refresh() {
+        try {
+            cfg = await api.GET("aux/config");
+            status = await api.GET("aux/status");
+        } catch (e) {
+            console.error("Failed to load aux config/status:", e);
+        }
+    }
+
+    async function save() {
+        if (!cfg) return;
+        busy = true;
+        try {
+            await api.PUT("aux/config/save", cfg);
+            await refresh();
+        } catch (e) {
+            console.error("Failed to save aux config:", e);
+            throw e;
+        } finally {
+            busy = false;
+        }
+    }
+
+    // Mark the root config as modified whenever an auxiliary axis
+    // field is edited, so the master Save button highlights and
+    // the user knows there are unsaved changes.
+    function markDirty() {
+        try {
+            const root = (window as any).$root || (window as any).Vue?.root;
+            if (root && "modified" in root) root.modified = true;
+        } catch (_e) {}
+        // Also dispatch a generic event the Vue root listens for.
+        window.dispatchEvent(new CustomEvent("onefin:dirty"));
+    }
+</script>
+
+<div class="a-axis-settings">
+    {#if !cfg}
+        <p class="tip">Loading A axis configuration...</p>
+    {:else}
+        <div class="status">
+            {#if status}
+                <span>
+                    Status:
+                    {#if !status.enabled}
+                        disabled
+                    {:else if !status.present}
+                        offline
+                    {:else if status.homed}
+                        homed at {status.pos_mm.toFixed(3)} mm
+                    {:else}
+                        connected, unhomed
+                    {/if}
+                </span>
+            {/if}
+        </div>
+
+        <div class="pure-form pure-form-aligned" on:input={markDirty} on:change={markDirty}>
+            <fieldset>
+                <div class="pure-control-group" title="Enable the auxiliary axis (auxcnc-driven A). Edit aux.json to toggle.">
+                    <label for="enabled">enabled</label>
+                    <input id="enabled" type="checkbox" checked={cfg.enabled} disabled />
+                    <label for="" class="units">(edit aux.json)</label>
+                </div>
+
+                <div class="pure-control-group" title="Serial port for the auxcnc ESP32.">
+                    <label for="port">serial port</label>
+                    <input id="port" type="text" bind:value={cfg.port} />
+                </div>
+
+                <div class="pure-control-group" title="Serial baud rate.">
+                    <label for="baud">baud</label>
+                    <input id="baud" type="number" bind:value={cfg.baud} min={1200} step={1} />
+                </div>
+            </fieldset>
+
+            <h3>Mechanics</h3>
+            <fieldset>
+                <div class="pure-control-group" title="Logical steps per mm of axis travel.">
+                    <label for="steps_per_mm">steps per mm</label>
+                    <input id="steps_per_mm" type="number" bind:value={cfg.steps_per_mm} step="any" />
+                    <label for="" class="units">steps/mm</label>
+                </div>
+
+                <div class="pure-control-group" title="Direction sign: +1 or -1. Flip if A+ moves the wrong way.">
+                    <label for="dir_sign">direction sign</label>
+                    <select id="dir_sign" bind:value={cfg.dir_sign}>
+                        <option value={1}>+1</option>
+                        <option value={-1}>-1</option>
+                    </select>
+                </div>
+
+                <div class="pure-control-group" title="gcode axis letter exposed to the planner. Default 'a' (the standard 4th axis).">
+                    <label for="axis_letter">axis letter</label>
+                    <select id="axis_letter" bind:value={cfg.axis_letter}>
+                        <option value="a">A</option>
+                        <option value="b">B</option>
+                        <option value="c">C</option>
+                    </select>
+                </div>
+
+                <div class="pure-control-group" title="Soft-limit minimum in mm.">
+                    <label for="min_mm">soft min</label>
+                    <input id="min_mm" type="number" bind:value={cfg.min_mm} step="any" />
+                    <label for="" class="units">mm</label>
+                </div>
+
+                <div class="pure-control-group" title="Soft-limit maximum in mm.">
+                    <label for="max_mm">soft max</label>
+                    <input id="max_mm" type="number" bind:value={cfg.max_mm} step="any" />
+                    <label for="" class="units">mm</label>
+                </div>
+            </fieldset>
+
+            <h3>Z-A Coupling</h3>
+            <p class="tip">
+                The auxiliary tool hangs below the Z spindle. Beyond a small
+                Z descent the two collide unless A drops with Z. The rule
+                in machine coordinates is
+                <code>A &minus; Z &le; (A_home &minus; Z_home) + clearance</code>.
+                When enabled, the planner refuses moves that would violate
+                it and the gcode preprocessor injects pre-position A moves
+                into uploaded files.
+            </p>
+            <fieldset>
+                <div class="pure-control-group" title="Master switch for the Z-A interlock. When off, no checks are performed.">
+                    <label for="couple_z_enabled">enable coupling</label>
+                    <input id="couple_z_enabled" type="checkbox" bind:checked={cfg.couple_z_enabled} />
+                </div>
+
+                <div class="pure-control-group" title="How far Z may descend below its home position before A must move with it.">
+                    <label for="couple_z_clearance_mm">Z clearance</label>
+                    <input id="couple_z_clearance_mm" type="number" bind:value={cfg.couple_z_clearance_mm} step="any" />
+                    <label for="" class="units">mm</label>
+                </div>
+
+                <div class="pure-control-group" title="Z's machine position when homed. Almost always 0.">
+                    <label for="z_home_mm">Z home position</label>
+                    <input id="z_home_mm" type="number" bind:value={cfg.z_home_mm} step="any" />
+                    <label for="" class="units">mm</label>
+                </div>
+            </fieldset>
+
+            <h3>Planner Limits</h3>
+            <fieldset>
+                <div class="pure-control-group" title="Maximum velocity used by gplan trajectory planning.">
+                    <label for="max_velocity_m_per_min">max velocity</label>
+                    <input id="max_velocity_m_per_min" type="number" bind:value={cfg.max_velocity_m_per_min} step="any" />
+                    <label for="" class="units">m/min</label>
+                </div>
+
+                <div class="pure-control-group" title="Maximum acceleration used by gplan trajectory planning.">
+                    <label for="max_accel_km_per_min2">max acceleration</label>
+                    <input id="max_accel_km_per_min2" type="number" bind:value={cfg.max_accel_km_per_min2} step="any" />
+                    <label for="" class="units">km/min²</label>
+                </div>
+
+                <div class="pure-control-group" title="Maximum jerk used by gplan trajectory planning.">
+                    <label for="max_jerk_km_per_min3">max jerk</label>
+                    <input id="max_jerk_km_per_min3" type="number" bind:value={cfg.max_jerk_km_per_min3} step="any" />
+                    <label for="" class="units">km/min³</label>
+                </div>
+
+                <div class="pure-control-group" title="Informational max feed; rate caps live on the ESP via step_max_sps.">
+                    <label for="max_feed_mm_min">max feed</label>
+                    <input id="max_feed_mm_min" type="number" bind:value={cfg.max_feed_mm_min} step="any" />
+                    <label for="" class="units">mm/min</label>
+                </div>
+            </fieldset>
+
+            <h3>Homing</h3>
+            <fieldset>
+                <div class="pure-control-group" title="Direction the axis moves when looking for the home limit switch.">
+                    <label for="home_dir">home direction</label>
+                    <select id="home_dir" bind:value={cfg.home_dir}>
+                        <option value="-">- (toward A-)</option>
+                        <option value="+">+ (toward A+)</option>
+                    </select>
+                </div>
+
+                <div class="pure-control-group" title="Axis position assigned when homing completes.">
+                    <label for="home_position_mm">home position</label>
+                    <input id="home_position_mm" type="number" bind:value={cfg.home_position_mm} step="any" />
+                    <label for="" class="units">mm</label>
+                </div>
+
+                <div class="pure-control-group" title="Fast seek rate during homing search.">
+                    <label for="home_fast_sps">fast seek</label>
+                    <input id="home_fast_sps" type="number" bind:value={cfg.home_fast_sps} step={1} min={1} />
+                    <label for="" class="units">steps/s</label>
+                </div>
+
+                <div class="pure-control-group" title="Slow seek rate during homing latch.">
+                    <label for="home_slow_sps">slow seek</label>
+                    <input id="home_slow_sps" type="number" bind:value={cfg.home_slow_sps} step={1} min={1} />
+                    <label for="" class="units">steps/s</label>
+                </div>
+
+                <div class="pure-control-group" title="Backoff after the limit triggers, before the slow seek.">
+                    <label for="home_backoff_steps">backoff</label>
+                    <input id="home_backoff_steps" type="number" bind:value={cfg.home_backoff_steps} step={1} min={0} />
+                    <label for="" class="units">steps</label>
+                </div>
+
+                <div class="pure-control-group" title="Maximum travel before homing aborts as a runaway.">
+                    <label for="home_maxtravel_steps">max travel</label>
+                    <input id="home_maxtravel_steps" type="number" bind:value={cfg.home_maxtravel_steps} step={1} min={1} />
+                    <label for="" class="units">steps</label>
+                </div>
+
+                <div class="pure-control-group" title="Limit switch active-low? Off = active-high.">
+                    <label for="limit_low">limit active low</label>
+                    <input id="limit_low" type="checkbox" bind:checked={cfg.limit_low} />
+                </div>
+            </fieldset>
+
+            <h3>Step Profile</h3>
+            <fieldset>
+                <div class="pure-control-group" title="Maximum step rate during normal moves.">
+                    <label for="step_max_sps">max rate</label>
+                    <input id="step_max_sps" type="number" bind:value={cfg.step_max_sps} step={1} min={1} />
+                    <label for="" class="units">steps/s</label>
+                </div>
+
+                <div class="pure-control-group" title="Acceleration in steps per second squared.">
+                    <label for="step_accel_sps2">acceleration</label>
+                    <input id="step_accel_sps2" type="number" bind:value={cfg.step_accel_sps2} step={1} min={1} />
+                    <label for="" class="units">steps/s²</label>
+                </div>
+
+                <div class="pure-control-group" title="Initial step rate at the start of a move.">
+                    <label for="step_start_sps">start rate</label>
+                    <input id="step_start_sps" type="number" bind:value={cfg.step_start_sps} step={1} min={1} />
+                    <label for="" class="units">steps/s</label>
+                </div>
+            </fieldset>
+
+            <div class="tip">
+                Changes are written to aux.json when you click the
+                master <strong>Save</strong> button at the bottom of the
+                settings rail. Homing rates and the limit polarity are
+                pushed to the ESP immediately; any running motion is
+                unaffected. Re-home the auxiliary axis after changing direction,
+                sign, or step settings.
+            </div>
+        </div>
+    {/if}
+</div>
+
+<style lang="scss">
+    .a-axis-settings {
+        .status {
+            margin-bottom: 1em;
+            font-size: 90%;
+            opacity: 0.8;
+        }
+
+        .actions {
+            margin-left: 210px;
+            margin-top: 1em;
+            display: flex;
+            align-items: center;
+            gap: 1em;
+        }
+
+        .save-msg {
+            font-style: italic;
+        }
+
+        .tip {
+            margin-left: 210px;
+            margin-top: 1em;
+            margin-bottom: 15px;
+            font-style: italic;
+            font-size: 90%;
+            line-height: 1.5;
+        }
+    }
+</style>

src/svelte-components/src/components/SettingsView.svelte

@@ -2,6 +2,10 @@
     import configTemplate from "../../../resources/config-template.json";
     import ScreenRotationDialog from "$dialogs/ScreenRotationDialog.svelte";
     import ConfigTemplatedInput from "./ConfigTemplatedInput.svelte";
+    // AAxisSettings is mounted directly by the V09 settings shell at
+    // #a-axis instead of being embedded here — see
+    // src/pug/templates/a-axis-view.pug.
+    // import AAxisSettings from "./AAxisSettings.svelte";
     import SetTimeDialog from "$dialogs/SetTimeDialog.svelte";
     import Button, { Label } from "@smui/button";
 
@@ -18,8 +22,8 @@
     <h1>Settings</h1>
 
     <div class="pure-form pure-form-aligned">
-        <h2>User Interface</h2>
-        <fieldset>
+        <h2 id="sec-display" data-sec="display">User Interface</h2>
+        <fieldset data-sec="display">
             <div class="pure-control-group">
                 <label for="screen-rotation" />
                 <Button
@@ -45,8 +49,8 @@
             </div> -->
         </fieldset>
 
-        <h2>Units</h2>
-        <fieldset>
+        <h2 id="sec-units" data-sec="display">Units</h2>
+        <fieldset data-sec="display">
             <ConfigTemplatedInput key={`settings.units`} />
             <div class="tip">
                 Note, units sets both the machine default units and the units used in motor configuration. GCode program-start,
@@ -54,13 +58,13 @@
             </div>
         </fieldset>
 
-        <h2>Easy Adapter</h2>
-        <fieldset>
+        <h2 id="sec-easy-adapter" data-sec="display">Easy Adapter</h2>
+        <fieldset data-sec="display">
             <ConfigTemplatedInput key={`settings.easy-adapter`} />
         </fieldset>
 
-        <h2>Probing</h2>
-        <fieldset>
+        <h2 id="sec-probing" data-sec="probing">Probing</h2>
+        <fieldset data-sec="probing">
             <ConfigTemplatedInput key={`settings.probing-prompts`} />
             <div class="tip">
                 Onefinity highly recommends that you keep the safety prompts
@@ -87,15 +91,19 @@
             {/each}
         </fieldset>
 
-        <fieldset>
-            <h2>GCode</h2>
+        <fieldset data-sec="gcode">
+            <h2 id="sec-gcode" data-sec="gcode">GCode</h2>
             {#each Object.keys(configTemplate.gcode) as key}
                 <ConfigTemplatedInput key={`gcode.${key}`} />
             {/each}
         </fieldset>
 
-        <h2>Path Accuracy</h2>
-        <fieldset>
+        <!-- W Axis (auxcnc) is now its own routed page in the V09
+             settings shell (#a-axis). Keep the SettingsView free of
+             that section so we don't render it twice. -->
+
+        <h2 id="sec-path-accuracy" data-sec="gcode">Path Accuracy</h2>
+        <fieldset data-sec="gcode">
             <ConfigTemplatedInput key={`settings.max-deviation`} />
 
             <div class="tip">
@@ -118,8 +126,8 @@
             </div>
         </fieldset>
 
-        <h2>Cornering Speed (Advanced)</h2>
-        <fieldset>
+        <h2 id="sec-cornering" data-sec="gcode">Cornering Speed (Advanced)</h2>
+        <fieldset data-sec="gcode">
             <ConfigTemplatedInput key={`settings.junction-accel`} />
             <div class="tip">
                 Junction acceleration limits the cornering speed the planner

src/svelte-components/src/components/TextFieldWithOptions.svelte

@@ -51,7 +51,7 @@
     >
         <div slot="trailingIcon">
             {#if valid}
-                <Icon class="fa fa-check-circle-o" style="color: green;" />
+                <Icon class="fa fa-circle-check" style="color: green;" />
             {/if}
         </div>
         <HelperText persistent slot="helper">{helperText}</HelperText>

src/svelte-components/src/main.ts

@@ -6,6 +6,7 @@ matchAll.shim();
 import AdminNetworkView from "$components/AdminNetworkView.svelte";
 import SettingsView from "$components/SettingsView.svelte";
 import HelpView from "$components/HelpView.svelte";
+import AAxisSettings from "$components/AAxisSettings.svelte";
 import DialogHost, { showDialog } from "$dialogs/DialogHost.svelte";
 import { handleConfigUpdate, setDisplayUnits } from "$lib/ConfigStore";
 import { handleControllerStateUpdate } from "$lib/ControllerState";
@@ -22,6 +23,9 @@ export function createComponent(component: string, target: HTMLElement, props: R
         case "HelpView":
             return new HelpView({ target, props });
 
+        case "AAxisSettings":
+            return new AAxisSettings({ target, props });
+
         case "DialogHost":
             return new DialogHost({ target, props });