fix: Stabilize full-flow cassette keys and restore output files on replay

Three issues discovered and fixed after initial recording:

1. Agent workdir names not normalized — random animal names (e.g.
   "available-sheep") embedded in workspace paths caused key drift.
   Added AGENT_WORKDIR_RE to replace agent-workdirs/<name> with
   agent-workdirs/__AGENT__ in normalizer.ts.

2. Phase/task files missing on replay — plan/detail agents write output
   to .cw/output/ (phases/, tasks/) which the server reads on completion.
   The replay worker only emits JSONL; it doesn't re-execute file writes.
   Extended cassette format with outputFiles field and added capture
   (walkOutputDir) + restore (restoreOutputFiles) logic to process-manager.

3. Recording timeout too short — fixed CASSETTE_FLOW_TIMEOUT to be
   mode-aware: 60 min for recording runs, 5 min for replay.

Also commit the 4 recorded cassettes (discuss/plan/detail/execute)
that make the full-flow cassette test runnable in CI without API costs.

src/test/cassette/normalizer.ts

@@ -12,6 +12,10 @@ const NANOID_RE = /(?<![A-Za-z0-9])[A-Za-z0-9_-]{21}(?![A-Za-z0-9_-])/g;
 const ISO_TIMESTAMP_RE = /\d{4}-\d{2}-\d{2}T\d{2}:\d{2}:\d{2}(\.\d+)?(Z|[+-]\d{2}:\d{2})?/g;
 const UNIX_EPOCH_MS_RE = /\b1[0-9]{12}\b/g;
 const SESSION_NUM_RE = /\bsession[_\s-]?\d+\b/gi;
+// Agent worktree paths: agent-workdirs/<random-agent-name> (with or without trailing slash)
+// The agent name (e.g. "available-sheep") changes every run but is not a UUID or nanoid.
+// Stop at the first slash so the project name after it is preserved.
+const AGENT_WORKDIR_RE = /agent-workdirs\/[^\s/\\]+/g;
 
 /**
  * Normalize a prompt for stable cassette key generation.
@@ -23,6 +27,7 @@ const SESSION_NUM_RE = /\bsession[_\s-]?\d+\b/gi;
  * 3. ISO 8601 timestamps → __TIMESTAMP__
  * 4. Unix epoch milliseconds → __EPOCH__
  * 5. Session numbers → session__N__
+ * 6. Agent worktree path segment → agent-workdirs/__AGENT__/
  */
 export function normalizePrompt(prompt: string, workspaceRoot: string): string {
   let normalized = prompt;
@@ -36,6 +41,7 @@ export function normalizePrompt(prompt: string, workspaceRoot: string): string {
   normalized = normalized.replace(ISO_TIMESTAMP_RE, '__TIMESTAMP__');
   normalized = normalized.replace(UNIX_EPOCH_MS_RE, '__EPOCH__');
   normalized = normalized.replace(SESSION_NUM_RE, 'session__N__');
+  normalized = normalized.replace(AGENT_WORKDIR_RE, 'agent-workdirs/__AGENT__');
 
   return normalized;
 }

src/test/cassette/process-manager.ts

@@ -16,8 +16,8 @@
  * - Worktree file hash (detects content drift for execute-mode agents)
  */
 
-import { readFileSync, existsSync } from 'node:fs';
-import { join } from 'node:path';
+import { readFileSync, existsSync, mkdirSync, writeFileSync, readdirSync } from 'node:fs';
+import { join, dirname, relative } from 'node:path';
 import { ProcessManager } from '../../agent/process-manager.js';
 import type { StreamEvent } from '../../agent/providers/parsers/index.js';
 import type { FileTailer } from '../../agent/file-tailer.js';
@@ -35,10 +35,16 @@ interface PendingRecording {
   agentCwd: string;
 }
 
+interface PendingReplay {
+  cassette: CassetteEntry;
+  agentCwd: string;
+}
+
 export class CassetteProcessManager extends ProcessManager {
   private readonly _workspaceRoot: string;
   private readonly replayWorkerPath: string;
   private readonly pendingRecordings = new Map<number, PendingRecording>();
+  private readonly pendingReplays = new Map<number, PendingReplay>();
 
   constructor(
     workspaceRoot: string,
@@ -74,7 +80,9 @@ export class CassetteProcessManager extends ProcessManager {
     const existing = this.cassetteMode !== 'record' ? this.store.find(key) : null;
 
     if (existing) {
-      return this.replayFromCassette(agentId, agentName, cwd, env, providerName, existing, onEvent, onRawContent);
+      const result = this.replayFromCassette(agentId, agentName, cwd, env, providerName, existing, onEvent, onRawContent);
+      this.pendingReplays.set(result.pid, { cassette: existing, agentCwd: cwd });
+      return result;
     }
 
     if (this.cassetteMode === 'replay') {
@@ -97,18 +105,28 @@ export class CassetteProcessManager extends ProcessManager {
     onComplete: () => Promise<void>,
     getTailer: () => FileTailer | undefined,
   ): { cancel: () => void } {
-    const pending = this.pendingRecordings.get(pid);
-    if (!pending) {
-      // Replay mode — no recording to save; delegate to base implementation.
-      return super.pollForCompletion(agentId, pid, onComplete, getTailer);
+    const recording = this.pendingRecordings.get(pid);
+    if (recording) {
+      // Record mode — wrap onComplete to save the cassette before handing off.
+      return super.pollForCompletion(agentId, pid, async () => {
+        await this.saveCassette(recording);
+        this.pendingRecordings.delete(pid);
+        await onComplete();
+      }, getTailer);
     }
 
-    // Record mode — wrap onComplete to save the cassette before handing off.
-    return super.pollForCompletion(agentId, pid, async () => {
-      await this.saveCassette(pending);
-      this.pendingRecordings.delete(pid);
-      await onComplete();
-    }, getTailer);
+    const replay = this.pendingReplays.get(pid);
+    if (replay) {
+      // Replay mode — restore .cw/output/ files before onComplete so that
+      // readPhaseFiles / readTaskFiles / readProposalFiles find their data.
+      return super.pollForCompletion(agentId, pid, async () => {
+        this.restoreOutputFiles(replay.cassette, replay.agentCwd);
+        this.pendingReplays.delete(pid);
+        await onComplete();
+      }, getTailer);
+    }
+
+    return super.pollForCompletion(agentId, pid, onComplete, getTailer);
   }
 
   private async saveCassette(pending: PendingRecording): Promise<void> {
@@ -123,7 +141,8 @@ export class CassetteProcessManager extends ProcessManager {
 
     // Read signal.json from the agent working directory.
     let signalJson: Record<string, unknown> | null = null;
-    const signalPath = join(pending.agentCwd, '.cw', 'output', 'signal.json');
+    const outputDir = join(pending.agentCwd, '.cw', 'output');
+    const signalPath = join(outputDir, 'signal.json');
     if (existsSync(signalPath)) {
       try {
         signalJson = JSON.parse(readFileSync(signalPath, 'utf-8')) as Record<string, unknown>;
@@ -132,6 +151,16 @@ export class CassetteProcessManager extends ProcessManager {
       }
     }
 
+    // Capture all other files in .cw/output/ (phase files, task files, etc.)
+    const outputFiles: Record<string, string> = {};
+    if (existsSync(outputDir)) {
+      this.walkOutputDir(outputDir, outputDir, (relPath, content) => {
+        if (relPath !== 'signal.json') {
+          outputFiles[relPath] = content;
+        }
+      });
+    }
+
     const entry: CassetteEntry = {
       version: 1,
       key: pending.key,
@@ -140,12 +169,67 @@ export class CassetteProcessManager extends ProcessManager {
         signalJson,
         exitCode: 0,
         recordedAt: new Date().toISOString(),
+        outputFiles,
       },
     };
 
     this.store.save(pending.key, entry);
   }
 
+  /**
+   * Restore captured .cw/output/ files to the new agent working directory.
+   * Called before onComplete so that downstream readers (readPhaseFiles, etc.)
+   * find the expected files in place.
+   */
+  private restoreOutputFiles(cassette: CassetteEntry, agentCwd: string): void {
+    const { outputFiles, signalJson } = cassette.recording;
+    const outputDir = join(agentCwd, '.cw', 'output');
+
+    // Restore captured output files
+    if (outputFiles) {
+      for (const [relPath, content] of Object.entries(outputFiles)) {
+        const fullPath = join(outputDir, relPath);
+        mkdirSync(dirname(fullPath), { recursive: true });
+        writeFileSync(fullPath, content, 'utf-8');
+      }
+    }
+
+    // Write signal.json (the manager reads this to detect completion status)
+    if (signalJson) {
+      mkdirSync(outputDir, { recursive: true });
+      writeFileSync(join(outputDir, 'signal.json'), JSON.stringify(signalJson), 'utf-8');
+    }
+  }
+
+  private walkOutputDir(
+    baseDir: string,
+    currentDir: string,
+    callback: (relPath: string, content: string) => void,
+  ): void {
+    let entries;
+    try {
+      entries = readdirSync(currentDir, { withFileTypes: true });
+    } catch {
+      return;
+    }
+
+    for (const entry of entries) {
+      const fullPath = join(currentDir, entry.name);
+      const relPath = relative(baseDir, fullPath);
+
+      if (entry.isDirectory()) {
+        this.walkOutputDir(baseDir, fullPath, callback);
+      } else if (entry.isFile()) {
+        try {
+          const content = readFileSync(fullPath, 'utf-8');
+          callback(relPath, content);
+        } catch {
+          // Skip unreadable files
+        }
+      }
+    }
+  }
+
   private replayFromCassette(
     agentId: string,
     agentName: string,

src/test/cassette/types.ts

@@ -26,6 +26,13 @@ export interface CassetteRecording {
   exitCode: number;
   /** ISO timestamp when this cassette was recorded. */
   recordedAt: string;
+  /**
+   * All files the agent wrote to .cw/output/ (relative path → UTF-8 content),
+   * excluding signal.json (which is captured separately in signalJson).
+   * Restored during replay before onComplete fires so downstream readers
+   * (e.g. readPhaseFiles, readTaskFiles) see the expected directory contents.
+   */
+  outputFiles?: Record<string, string>;
 }
 
 export interface CassetteEntry {

src/test/integration/full-flow/full-flow-cassette.test.ts

@@ -43,8 +43,15 @@ import {
 // Constants
 // =============================================================================
 
-/** Total test timeout: 5 minutes (replay=seconds; 5min covers accidental record) */
-const CASSETTE_FLOW_TIMEOUT = 5 * 60_000;
+const RECORDING =
+  process.env.CW_CASSETTE_FORCE_RECORD === '1' || process.env.CW_CASSETTE_RECORD === '1';
+
+/**
+ * Test timeout.
+ * - Replay: 5 min (cassettes complete in seconds; cap is generous headroom)
+ * - Record: 60 min (real agents doing discuss/plan/detail/execute take API time)
+ */
+const CASSETTE_FLOW_TIMEOUT = RECORDING ? 60 * 60_000 : 5 * 60_000;
 
 const __dirname = dirname(fileURLToPath(import.meta.url));
 const CASSETTE_DIR =