fix(qconnect): bounded CMAF fallback when the CDN header-floods a track

Akamai answers small raw-url objects with ~106 headers, over hyper's
hard-coded 100-header h1 cap, so every reqwest fetch of those tracks
failed identically (streaming probe AND full download) and the track
never played — with the cause hidden by reqwest's Display. Now:
describe_reqwest_error() walks the source chain for logs; on the
header-flood signature the engine skips the doomed reqwest re-download
and falls back to play_track_resolved (CMAF, unaffected) plus an
explicit sync_current_to_id so the queue cursor follows the audio.
Any other failure keeps the previous behavior. Live-verified on the Pi
(DSOTM track 1 plays; gapless continues).

km

crates/qbz/src/qconnect_engine.rs

@@ -48,6 +48,28 @@ impl SlintRendererEngine {
     fn core(&self) -> &Arc<QbzCore<SlintAdapter>> {
         self.runtime.core()
     }
+
+    /// Last-resort load for tracks the raw-URL path cannot fetch (the CDN
+    /// header flood defeats every reqwest attempt — see
+    /// `remote_stream::is_header_flood_error`): the CMAF path is unaffected by
+    /// the h1 header cap. `play_track_resolved` does NOT move the queue cursor
+    /// (nothing on the QConnect path does — the shared driver's cursor sync
+    /// only fires on a playing->playing track edge), so sync it explicitly or
+    /// the now-playing truth keeps showing the PREVIOUS track while the
+    /// recovered one plays.
+    async fn play_via_cmaf(
+        &self,
+        track_id: u64,
+        quality: Quality,
+        start_position_secs: u64,
+    ) -> Result<(), String> {
+        self.core()
+            .play_track_resolved(track_id, quality, None, None, start_position_secs)
+            .await
+            .map_err(|err| format!("CMAF fallback for remote track {track_id}: {err}"))?;
+        self.core().sync_current_to_id(track_id).await;
+        Ok(())
+    }
 }
 
 #[async_trait]
@@ -138,7 +160,7 @@ impl QconnectRendererEngine for SlintRendererEngine {
             .map_err(|err| format!("resolve stream url for remote track {track_id}: {err}"))?;
 
         let player = self.core().player();
-        match crate::remote_stream::stream_remote_track_into_player(
+        let stream_result = crate::remote_stream::stream_remote_track_into_player(
             &player,
             track_id,
             duration_secs,
@@ -146,22 +168,46 @@ impl QconnectRendererEngine for SlintRendererEngine {
             &stream_url.url,
             "QConnect",
         )
-        .await
-        {
-            Ok(()) => Ok(()),
-            Err(stream_err) => {
-                log::warn!(
-                    "[QConnect] Streaming handoff unavailable for track {}: {}. Falling back to full download.",
-                    track_id,
-                    stream_err
-                );
-                let audio_data = download_remote_audio(&stream_url.url).await?;
+        .await;
+
+        let Err(stream_err) = stream_result else {
+            return Ok(());
+        };
+
+        // Akamai small-object header flood: SMALL raw-url objects come back
+        // with ~106 headers, over hyper's hard-coded 100-header h1 cap, so
+        // EVERY reqwest fetch of this URL fails — the full download would die
+        // the same death. Skip it and go straight to the CMAF last resort.
+        if crate::remote_stream::is_header_flood_error(&stream_err) {
+            log::warn!(
+                "[QConnect] Raw-URL streaming hit the CDN header flood for track {track_id}: {stream_err}. Skipping full download; last resort: CMAF."
+            );
+            return self
+                .play_via_cmaf(track_id, quality, start_position_secs)
+                .await;
+        }
+
+        log::warn!(
+            "[QConnect] Streaming handoff unavailable for track {}: {}. Falling back to full download.",
+            track_id,
+            stream_err
+        );
+        match download_remote_audio(&stream_url.url).await {
+            Ok(audio_data) => {
                 self.core()
                     .player()
                     .play_data(audio_data, track_id)
                     .map_err(|err| format!("play remote track {track_id}: {err}"))?;
                 Ok(())
             }
+            Err(download_err) if crate::remote_stream::is_header_flood_error(&download_err) => {
+                log::warn!(
+                    "[QConnect] Full download hit the CDN header flood for track {track_id}: {download_err}. Last resort: CMAF."
+                );
+                self.play_via_cmaf(track_id, quality, start_position_secs)
+                    .await
+            }
+            Err(download_err) => Err(download_err),
         }
     }
 
@@ -181,7 +227,12 @@ async fn download_remote_audio(url: &str) -> Result<Vec<u8>, String> {
         .header("User-Agent", "Mozilla/5.0")
         .send()
         .await
-        .map_err(|err| format!("download remote audio request failed: {err}"))?;
+        .map_err(|err| {
+            format!(
+                "download remote audio request failed: {}",
+                crate::remote_stream::describe_reqwest_error(&err)
+            )
+        })?;
 
     if !response.status().is_success() {
         return Err(format!(
@@ -190,9 +241,11 @@ async fn download_remote_audio(url: &str) -> Result<Vec<u8>, String> {
         ));
     }
 
-    let bytes = response
-        .bytes()
-        .await
-        .map_err(|err| format!("read remote audio bytes failed: {err}"))?;
+    let bytes = response.bytes().await.map_err(|err| {
+        format!(
+            "read remote audio bytes failed: {}",
+            crate::remote_stream::describe_reqwest_error(&err)
+        )
+    })?;
     Ok(bytes.to_vec())
 }

crates/qbz/src/remote_stream.rs

@@ -106,7 +106,7 @@ pub async fn probe_remote_stream_info(url: &str) -> Result<RemoteStreamInfo, Str
         .header("User-Agent", "Mozilla/5.0")
         .send()
         .await
-        .map_err(|err| format!("probe HEAD request failed: {err}"))?;
+        .map_err(|err| format!("probe HEAD request failed: {}", describe_reqwest_error(&err)))?;
 
     if !head_response.status().is_success() {
         return Err(format!(
@@ -129,7 +129,7 @@ pub async fn probe_remote_stream_info(url: &str) -> Result<RemoteStreamInfo, Str
         .header("Range", "bytes=0-65535")
         .send()
         .await
-        .map_err(|err| format!("probe range request failed: {err}"))?;
+        .map_err(|err| format!("probe range request failed: {}", describe_reqwest_error(&err)))?;
 
     if !range_response.status().is_success() {
         return Err(format!(
@@ -141,7 +141,7 @@ pub async fn probe_remote_stream_info(url: &str) -> Result<RemoteStreamInfo, Str
     let initial_bytes = range_response
         .bytes()
         .await
-        .map_err(|err| format!("read probe bytes failed: {err}"))?;
+        .map_err(|err| format!("read probe bytes failed: {}", describe_reqwest_error(&err)))?;
 
     let elapsed = start_time.elapsed();
     let speed_mbps = if elapsed.as_secs_f64() > 0.0 {
@@ -214,7 +214,12 @@ pub async fn download_and_stream_remote_track(
         .header("User-Agent", "Mozilla/5.0")
         .send()
         .await
-        .map_err(|err| format!("start remote streaming request failed: {err}"))?;
+        .map_err(|err| {
+            format!(
+                "start remote streaming request failed: {}",
+                describe_reqwest_error(&err)
+            )
+        })?;
 
     if !response.status().is_success() {
         return Err(format!(
@@ -229,7 +234,8 @@ pub async fn download_and_stream_remote_track(
     let mut last_log_time = Instant::now();
 
     while let Some(chunk_result) = stream.next().await {
-        let chunk = chunk_result.map_err(|err| format!("remote streaming chunk failed: {err}"))?;
+        let chunk = chunk_result
+            .map_err(|err| format!("remote streaming chunk failed: {}", describe_reqwest_error(&err)))?;
         bytes_received += chunk.len() as u64;
 
         if let Err(err) = writer.push_chunk(&chunk) {
@@ -284,3 +290,29 @@ pub async fn download_and_stream_remote_track(
 
     Ok(())
 }
+
+/// reqwest's `Display` hides the source chain — which is exactly where the
+/// diagnosis lives (Akamai's >100-header small-object flood surfaces as hyper's
+/// "message head is too large" two levels down). Walk `source()` and join the
+/// chain so logs AND signature matching see the real cause.
+pub fn describe_reqwest_error(err: &reqwest::Error) -> String {
+    use std::error::Error as _;
+    let mut out = err.to_string();
+    let mut source = err.source();
+    while let Some(cause) = source {
+        out.push_str(": ");
+        out.push_str(&cause.to_string());
+        source = cause.source();
+    }
+    out
+}
+
+/// True when an error message (already chain-expanded by
+/// [`describe_reqwest_error`]) shows hyper's hard-coded h1 100-header cap.
+/// Akamai answers SMALL raw-url objects with ~106 headers (the `X-AK-GRN` /
+/// `X-AK-FWD-ERROR: ERR_POC_FWD_OBJ_TOO_SMALL` flood), so EVERY reqwest fetch
+/// of such an URL fails this way — streaming probe and full download alike.
+pub fn is_header_flood_error(message: &str) -> bool {
+    let haystack = message.to_ascii_lowercase();
+    haystack.contains("message head is too large") || haystack.contains("too many headers")
+}

crates/qbzd/src/qconnect/engine.rs

@@ -97,6 +97,28 @@ impl DaemonRendererEngine {
     fn core(&self) -> &Arc<QbzCore<DaemonAdapter>> {
         self.runtime.core()
     }
+
+    /// Last-resort load for tracks the raw-URL path cannot fetch (the CDN
+    /// header flood defeats every reqwest attempt — see
+    /// `remote_stream::is_header_flood_error`): the CMAF path is unaffected by
+    /// the h1 header cap. `play_track_resolved` does NOT move the queue cursor
+    /// (nothing on the QConnect path does — the shared driver's cursor sync
+    /// only fires on a playing->playing track edge), so sync it explicitly or
+    /// `qbzd status` / the local now-playing truth keep showing the PREVIOUS
+    /// track while the recovered one plays.
+    async fn play_via_cmaf(
+        &self,
+        track_id: u64,
+        quality: Quality,
+        start_position_secs: u64,
+    ) -> Result<(), String> {
+        self.core()
+            .play_track_resolved(track_id, quality, None, None, start_position_secs)
+            .await
+            .map_err(|err| format!("CMAF fallback for remote track {track_id}: {err}"))?;
+        self.core().sync_current_to_id(track_id).await;
+        Ok(())
+    }
 }
 
 #[async_trait]
@@ -198,7 +220,7 @@ impl QconnectRendererEngine for DaemonRendererEngine {
             .map_err(|err| format!("resolve stream url for remote track {track_id}: {err}"))?;
 
         let player = self.core().player();
-        match super::remote_stream::stream_remote_track_into_player(
+        let stream_result = super::remote_stream::stream_remote_track_into_player(
             &player,
             track_id,
             duration_secs,
@@ -206,22 +228,46 @@ impl QconnectRendererEngine for DaemonRendererEngine {
             &stream_url.url,
             "QConnect",
         )
-        .await
-        {
-            Ok(()) => Ok(()),
-            Err(stream_err) => {
-                log::warn!(
-                    "[QConnect] Streaming handoff unavailable for track {}: {}. Falling back to full download.",
-                    track_id,
-                    stream_err
-                );
-                let audio_data = download_remote_audio(&stream_url.url).await?;
+        .await;
+
+        let Err(stream_err) = stream_result else {
+            return Ok(());
+        };
+
+        // Akamai small-object header flood: SMALL raw-url objects come back
+        // with ~106 headers, over hyper's hard-coded 100-header h1 cap, so
+        // EVERY reqwest fetch of this URL fails — the full download would die
+        // the same death. Skip it and go straight to the CMAF last resort.
+        if super::remote_stream::is_header_flood_error(&stream_err) {
+            log::warn!(
+                "[QConnect] Raw-URL streaming hit the CDN header flood for track {track_id}: {stream_err}. Skipping full download; last resort: CMAF."
+            );
+            return self
+                .play_via_cmaf(track_id, quality, start_position_secs)
+                .await;
+        }
+
+        log::warn!(
+            "[QConnect] Streaming handoff unavailable for track {}: {}. Falling back to full download.",
+            track_id,
+            stream_err
+        );
+        match download_remote_audio(&stream_url.url).await {
+            Ok(audio_data) => {
                 self.core()
                     .player()
                     .play_data(audio_data, track_id)
                     .map_err(|err| format!("play remote track {track_id}: {err}"))?;
                 Ok(())
             }
+            Err(download_err) if super::remote_stream::is_header_flood_error(&download_err) => {
+                log::warn!(
+                    "[QConnect] Full download hit the CDN header flood for track {track_id}: {download_err}. Last resort: CMAF."
+                );
+                self.play_via_cmaf(track_id, quality, start_position_secs)
+                    .await
+            }
+            Err(download_err) => Err(download_err),
         }
     }
 
@@ -241,7 +287,12 @@ async fn download_remote_audio(url: &str) -> Result<Vec<u8>, String> {
         .header("User-Agent", "Mozilla/5.0")
         .send()
         .await
-        .map_err(|err| format!("download remote audio request failed: {err}"))?;
+        .map_err(|err| {
+            format!(
+                "download remote audio request failed: {}",
+                super::remote_stream::describe_reqwest_error(&err)
+            )
+        })?;
 
     if !response.status().is_success() {
         return Err(format!(
@@ -250,10 +301,12 @@ async fn download_remote_audio(url: &str) -> Result<Vec<u8>, String> {
         ));
     }
 
-    let bytes = response
-        .bytes()
-        .await
-        .map_err(|err| format!("read remote audio bytes failed: {err}"))?;
+    let bytes = response.bytes().await.map_err(|err| {
+        format!(
+            "read remote audio bytes failed: {}",
+            super::remote_stream::describe_reqwest_error(&err)
+        )
+    })?;
     Ok(bytes.to_vec())
 }
 

crates/qbzd/src/qconnect/remote_stream.rs

@@ -108,7 +108,7 @@ pub async fn probe_remote_stream_info(url: &str) -> Result<RemoteStreamInfo, Str
         .header("User-Agent", "Mozilla/5.0")
         .send()
         .await
-        .map_err(|err| format!("probe HEAD request failed: {err}"))?;
+        .map_err(|err| format!("probe HEAD request failed: {}", describe_reqwest_error(&err)))?;
 
     if !head_response.status().is_success() {
         return Err(format!(
@@ -131,7 +131,7 @@ pub async fn probe_remote_stream_info(url: &str) -> Result<RemoteStreamInfo, Str
         .header("Range", "bytes=0-65535")
         .send()
         .await
-        .map_err(|err| format!("probe range request failed: {err}"))?;
+        .map_err(|err| format!("probe range request failed: {}", describe_reqwest_error(&err)))?;
 
     if !range_response.status().is_success() {
         return Err(format!(
@@ -143,7 +143,7 @@ pub async fn probe_remote_stream_info(url: &str) -> Result<RemoteStreamInfo, Str
     let initial_bytes = range_response
         .bytes()
         .await
-        .map_err(|err| format!("read probe bytes failed: {err}"))?;
+        .map_err(|err| format!("read probe bytes failed: {}", describe_reqwest_error(&err)))?;
 
     let elapsed = start_time.elapsed();
     let speed_mbps = if elapsed.as_secs_f64() > 0.0 {
@@ -217,7 +217,12 @@ pub async fn download_and_stream_remote_track(
         .header("User-Agent", "Mozilla/5.0")
         .send()
         .await
-        .map_err(|err| format!("start remote streaming request failed: {err}"))?;
+        .map_err(|err| {
+            format!(
+                "start remote streaming request failed: {}",
+                describe_reqwest_error(&err)
+            )
+        })?;
 
     if !response.status().is_success() {
         return Err(format!(
@@ -232,7 +237,8 @@ pub async fn download_and_stream_remote_track(
     let mut last_log_time = Instant::now();
 
     while let Some(chunk_result) = stream.next().await {
-        let chunk = chunk_result.map_err(|err| format!("remote streaming chunk failed: {err}"))?;
+        let chunk = chunk_result
+            .map_err(|err| format!("remote streaming chunk failed: {}", describe_reqwest_error(&err)))?;
         bytes_received += chunk.len() as u64;
 
         if let Err(err) = writer.push_chunk(&chunk) {
@@ -287,3 +293,29 @@ pub async fn download_and_stream_remote_track(
 
     Ok(())
 }
+
+/// reqwest's `Display` hides the source chain — which is exactly where the
+/// diagnosis lives (Akamai's >100-header small-object flood surfaces as hyper's
+/// "message head is too large" two levels down). Walk `source()` and join the
+/// chain so logs AND signature matching see the real cause.
+pub fn describe_reqwest_error(err: &reqwest::Error) -> String {
+    use std::error::Error as _;
+    let mut out = err.to_string();
+    let mut source = err.source();
+    while let Some(cause) = source {
+        out.push_str(": ");
+        out.push_str(&cause.to_string());
+        source = cause.source();
+    }
+    out
+}
+
+/// True when an error message (already chain-expanded by
+/// [`describe_reqwest_error`]) shows hyper's hard-coded h1 100-header cap.
+/// Akamai answers SMALL raw-url objects with ~106 headers (the `X-AK-GRN` /
+/// `X-AK-FWD-ERROR: ERR_POC_FWD_OBJ_TOO_SMALL` flood), so EVERY reqwest fetch
+/// of such an URL fails this way — streaming probe and full download alike.
+pub fn is_header_flood_error(message: &str) -> bool {
+    let haystack = message.to_ascii_lowercase();
+    haystack.contains("message head is too large") || haystack.contains("too many headers")
+}