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perf: record rejected overlay allocation
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Neil
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# Phase 1 on-demand app-overlay chunk allocation audit — 2026-07-30
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**Result:** rejected. A shared deferred app-overlay source module successfully deferred the
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Markdown template picker and recent-tab switcher visual code, but Rolldown again extracted
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the same 63,446-byte utility chunk into all three static renderer closures. One narrowly
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scoped `advancedChunks` arm removed that extra file but recursively captured 847,208 bytes
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and made the alleged deferred capability static in every renderer entry. All source,
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configuration, test, output, and budget changes were restored; only this negative audit is
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retained.
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## Inputs and allocation model
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The fresh baseline is checkpoint `e6f4772e82fa8b75c52baf14aa026032a844982b`.
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The two preceding negative reports predicted the two allocation hazards:
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- the Markdown picker boundary extracted `utils-CpTw4IZK.js`, 63,446 raw / 13,707 gzip;
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- the recent-tab boundary separately extracted a Lucide factory chunk.
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Rolldown `1.0.0-beta.53`'s installed type documentation says `manualChunks` is deprecated and
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translated to an `advancedChunks` group. An advanced group captures matched-module
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dependencies recursively by default, group constraints fall back to automatic chunking
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when unmet, higher priority wins, and separator-safe regular expressions should use
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`[\\/]`. Those contracts ruled out a broad vendor split and made recursive dependency
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capture an explicit measured risk rather than an assumption.
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## Prototype ownership and behavior
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The combined arm used one concretely owned loader:
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`loadDeferredAppOverlayModule()` → `DeferredAppOverlaySurfaces.tsx`
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It did not reuse the Settings loader. The dynamic module exported only
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`MarkdownTemplatePickerSurface` and `RecentTabSwitcherSurface`; narrow eager hosts remained
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at the exact existing `App.tsx` error-boundary positions and inside the same tooltip,
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confirmation, and link-routing providers.
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The Markdown host retained the singleton request listener, active request/ref, replacement
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cancellation, unmount cancellation, and once-protected resolver. It latched the shared
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surface after the first delivered request, so zero-template and no-listener requests still
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resolved immediately to blank without loading, replacement remained valid while the chunk
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was unresolved, and the loaded instance stayed mounted across later close/reopen cycles.
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The recent-tab host retained native and capture-phase DOM input ownership, current-store
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model construction, direction, selected identity, commit/cancel, and cleanup. Only a
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successful open latched the shared surface. Commit remained controller-owned while the
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chunk was unresolved; Escape and blur still canceled; native and DOM ordering, user and
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platform bindings, MRU/sequential models, accessibility, copy, tokens, icons, portal, and
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mounted continuity were unchanged.
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Candidate-focused tests covered no-request/rejected-open deferral, Markdown blank fallbacks,
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replacement, unmount, once-only resolution, selection identity, both retry keys, recent-tab
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unresolved-chunk commit, native input, DOM capture ordering, cancellation, cleanup, and
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mounted continuity. The focused candidate/config run passed 7 files and 55 tests.
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## Fresh measured arms
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- A, accepted source: `/tmp/orca-overlay-allocation-a.9ucEuF`
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- B, combined source grouping: `/tmp/orca-overlay-allocation-b-combined.wo0HK6`
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- C, one allocation intervention: `/tmp/orca-overlay-allocation-c-advanced.aJlNSR`
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- Restored A confirmation: `/tmp/orca-overlay-allocation-restored.lNm0Of`
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All builds transformed 2,003 main and 17 preload modules. A transformed 9,186 renderer
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modules; B and C transformed 9,187. Every build emitted only the two existing
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`::highlight(...)` CSS parser warnings.
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| Static closure | A raw / gzip | B raw / gzip | B raw / gzip change | A JS/CSS | B JS/CSS |
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| ---------------- | --------------------: | --------------------: | ------------------: | -------: | -------: |
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| Main window | 8,416,540 / 1,877,823 | 8,412,795 / 1,877,323 | -3,745 / -500 | 292 / 2 | 293 / 2 |
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| Dashboard popout | 4,507,253 / 984,615 | 4,507,716 / 985,055 | +463 / +440 | 77 / 2 | 78 / 2 |
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| Web renderer | 4,360,652 / 928,355 | 4,361,076 / 928,746 | +424 / +391 | 33 / 1 | 34 / 1 |
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B emitted one documented deferred capability file:
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- `assets/DeferredAppOverlaySurfaces-CzfSTmPr.js`
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- 6,532 raw / 1,915 gzip
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- SHA-256 `21630582b6d9563c1eb687cefe88dac50eeedb94c637df3d0d3758ec9f89a074`
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The surface was absent from all static closures. Its imports nevertheless caused the exact
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previous Markdown hazard to recur:
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- `assets/utils-CpTw4IZK.js`
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- 63,446 raw / 13,707 gzip
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- SHA-256 `de0bc0dc34d80e5522f95e3e1e0e0d6bd5f76105c028e5246d988919f44a06fa`
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The exact B static paths were:
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- `index.html` → `index-CQHAljKw.js` → `checkbox-DsU9bKK9.js` →
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`utils-CpTw4IZK.js`
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- `popout.html` → `popout-C0YDWIOW.js` → `dropdown-menu-D0X_LBOW.js` →
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`utils-CpTw4IZK.js`
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- `web-index.html` → `web-Btz34HG8.js` → `label-CVwIOaA-.js` →
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`utils-CpTw4IZK.js`
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Thus combined source grouping improved main raw/gzip but increased both unrelated renderer
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raw totals, gzip totals, and JavaScript counts. It failed retention.
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## Allocation arm
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C added one separator-safe, exact-source `advancedChunks` group named
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`deferred-app-overlays`, with priority 10 and the documented default recursive dependency
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capture. A focused deterministic config test proved that the predicate matched the target
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on POSIX and Windows paths and rejected a test file and Settings.
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| Static closure | C raw / gzip | Change from A | C JS/CSS | JS/CSS change |
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| ---------------- | --------------------: | ----------------: | -------: | ------------: |
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| Main window | 8,410,490 / 1,873,465 | -6,050 / -4,358 | 280 / 2 | -12 / 0 |
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| Dashboard popout | 4,532,625 / 988,687 | +25,372 / +4,072 | 67 / 2 | -10 / 0 |
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| Web renderer | 4,455,290 / 949,915 | +94,638 / +21,560 | 29 / 1 | -4 / 0 |
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Recursive capture emitted:
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- `assets/deferred-app-overlays-BZIPmf1j.js`
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- 847,208 raw / 264,564 gzip
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- SHA-256 `017386baa10078d9be72026505d72b1c8aa653d82f85ebf16c6d4baa56aa7517`
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The nominal dynamic entry became a 189-byte facade, while the 847-kilobyte capability was a
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direct static import of `index-DbgAJPlm.js`, `popout-C1lyyCh5.js`, and `web-CvH36JNi.js`.
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C reduced file counts but defeated on-demand allocation and materially regressed popout and
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web raw/gzip totals. No second bundler intervention was attempted.
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## Exact manifests and validation
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The manifest hashes below use sorted
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`path<TAB>raw<TAB>gzip<TAB>file-sha256` rows. Complete renderer validation checked every
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manifest import key, dynamic-import key, emitted JavaScript/CSS file, and declared asset;
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all paths resolved beneath the artifact root. No entry's static graph imported another HTML
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entry.
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| Evidence | A | B | C |
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| --------------------------------- | ------------------------------------------------------------------------ | ------------------------------------------------------------------------ | ------------------------------------------------------------------------ |
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| Renderer manifest entries/hash | 778 / `92ad617f8c8aee6d4c4a23622f524266cbe9c93b3fe65544d1acb833dc3f0d67` | 781 / `822391bb7cca41790c9972d31b907854d63c5a139f28517b54dee16fc3bef151` | 767 / `b2fbd6ec8671c03dde0a0b997e8e0fec5ada8e543cd1c6e6736c47ace2cf8d04` |
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| Static/dynamic edges | 6,247 / 213 | 6,323 / 214 | 5,745 / 214 |
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| Emitted references / failures | 860 / 0 | 863 / 0 | 849 / 0 |
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| Renderer files / tree hash | 787 / `ab7d45d0f56191bca710c0fb0746e4900d953a971e43a80ff92123925784a30a` | 790 / `f28e3933578d9b5c2d1742f1d27ea6b34f0871cd1c2544d2480f8aae089e3ff0` | 776 / `de06487083c2f409de3cb751c1b80d9af2eefa01034c0b5a04ee78f53d9dd555` |
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| Complete output files / tree hash | 972 / `eee5f7a4dbe84c00c74e6605aa19fbedf43e1ce8c6aaa2a760d0bfda07df8e1f` | 975 / `5e4170e379d74db1de0c5effad47655c26d36dcea110cdb608d0d746bf1d1648` | 961 / `4f090bb9f918e576efbda927602872e9711558059df97e37f912e6d7413ca7fc` |
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| Main closure rows/hash | 294 / `cd84b2b8294f67ba89ae7afa6067664ed7e920c3ea8f0ae239bc47fb15debf2c` | 295 / `73a8d2e8443e99c6b4c29731d0db5a9fe96ed5efcd8dc0fcd533fe152e6e24f1` | 282 / `f2f3f7581fa5bade10d48e1bb4479ac406a933424ca25d04d6d18dc37391d020` |
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| Popout closure rows/hash | 79 / `f5f2e8ef7e1f7685321c05d3940484b8bc51d54f916f8f01ec8709cb006fbf87` | 80 / `c0b4381dd9a001ea6eaaa1121129ec2b1f1cc885c2a51218173b5f6e4cc73710` | 69 / `6b267d5bc49c91d97b2a61dbf21b3a8c563e0fc4d2efaedd447ca4430ba9bebd` |
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| Web closure rows/hash | 34 / `076e3afcb45d1d195eef95a88cd6f2574f4b6fb92d158188cd5378f4899a039f` | 35 / `72120bff1ca31bafd455648fd09796df125e5cce826a0b2aed09d4ed0c03e162` | 30 / `702c3bc77887293a8dc1316f32a5172fc582cba12e28f11ccd3de9aec540efe1` |
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Electron main and preload were byte-identical across A, B, and C:
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| Entry | Raw / gzip | SHA-256 |
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| ------- | ----------------: | ------------------------------------------------------------------ |
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| Main | 776,873 / 174,092 | `6e75b9d4862f1219c23f16d6c920004167d7dae1995498caaacc5354a9d8f8fd` |
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| Preload | 130,798 / 20,642 | `c388a39cdca9609760e286d95b87ad1e53793720450e507f830ff1f6c5bd259f` |
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## Restoration and checks
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The accepted renderer-index raw budget remains 8,466,347, preserving exactly 49,807 bytes
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over A. No budget was raised or changed. After both arms were rejected, all prototype,
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allocation, focused-test, and budget edits were removed with patch edits rather than
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checkout/reset.
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- Candidate behavior plus deterministic allocation predicate: 7 files and 55 tests passed.
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- `pnpm run typecheck:web`: passed on the candidate.
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- Restored recent-tab native/browser/model/policy and Markdown creation run: 8 files and 217
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tests passed.
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- Restored `pnpm run typecheck:web`: passed.
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- Targeted `oxlint --deny-warnings` and `oxfmt --check`: passed.
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- `pnpm run check:max-lines-ratchet`: passed.
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- `pnpm run check:electron-bundle-budgets`: passed against the restored A output.
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- Complete restored manifest/path/entry-cycle validation: passed.
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- The restored 972-file output tree was byte-identical to fresh A, with tree hash
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`eee5f7a4dbe84c00c74e6605aa19fbedf43e1ce8c6aaa2a760d0bfda07df8e1f`.
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- `git diff --check`: passed.
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No packaged launch smoke was run on macOS, Linux, or Windows. The builds and manifest
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validation ran on this macOS worktree; packaged cross-platform launch behavior remains
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unresolved.
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