fix(newos4): one arg-coercion boundary + binary-safe gunzip + clean boot log (v4.6.159)

1. Tool arguments are coerced once, at the dispatch boundary (module-aiassist.js)
   - _coerceToolArgs(name, a) at :1584 reads the tool's own JSON schema and, for every
     declared string prop, converts number/boolean with String() and object/array with
     JSON.stringify (never "[object Object]"); declared integer/number props accept
     unambiguous numeric strings. null/undefined stay absent so the handlers' defaults
     and _pathArg still own "no value given".
   - Called at both dispatch boundaries: runTool (:2650) and runModuleTool (:3565 —
     reachable from view_module and from ship_module -> test_module/health_check, which
     have their own parse+switch).
   - A JSON body of "null" or "[1,2]" parses to a non-object; both sites normalise to {}
     before any handler reads a.field.
   - The 26 handlers keep their `a.x || ''` reads: `|| ''` catches only FALSY, which is
     how a truthy number or object reached .trim()/.split()/.replace() and filed one
     auto-report per tool (user_get "key.split is not a function", create_skill,
     patch_skill, delegate_task "task.substring is not a function", create_mindmap,
     web_fetch, list_skills, ship_module).

2. gunzip is binary-safe (cryptogzip.js — plan 2026-11-03 T3, the last open task)
   - _cmdGunzip used _vfsRead + _gunzipString (base64-only), so a real .gz fetched with
     wget reported "not valid base64 input (illegal character \u001f)" and could not be
     decompressed at all. It now reads bytes (_vfsReadBytes handles both the module's
     base64 output and raw Latin-1 bytes), checks the 1f 8b magic, and reports
     "not a gzip file" for non-gzip input without writing or deleting anything.
     The module's own gzip output still round-trips.

3. Boot log is clean (terminal.js)
   - Seven _safeRegister() calls for Editor/Shell/Alias/Finder/FileManager/Diff/BusyBox
     were guaranteed no-ops: those classes are declared in critical-ext-bundle.js, a
     <script> after module-loader.js, so they do not exist yet when new WebX11Terminal()
     runs; adding them to the registry map would still resolve to undefined. Removed with
     a comment — the ext bundle registers each one on load.
   - SimpleGUIModule IS a core class but was missing from _safeRegister's registry map,
     so the fallback could never restore it. Added.

4. New guard: admin/scripts/verify-plan-age.py + profile wrapper plan-age-guard.sh
   (cron newos4-plan-age-guard, no_agent, daily 07:10). Silent when healthy; reports
   plans marked <!-- autonomy: review --> with no execution stamp older than 72 h —
   the process gap that let four fix plans sit for six days before v4.6.158. Read-only
   by construction (148 real plans byte+mtime identical before/after a run), rc=2 when
   the directory cannot be scanned, --strict opt-in so a report is never recorded as a
   crashed guard.

Verified: 37/37 node tests, 3 new test files and 631 new assertions (613 arg-coercion,
18 gunzip); test-cryptogzip-guard's C8 updated because it pinned the old misleading
"not valid base64" message. Independent orchestrator checks: all 66 declared string
props across 58 tool defs coerced under 4 hostile shapes; positive cases untouched
(string content not double-encoded, numbers still numbers, null still absent, unknown
tool identity preserved). Served bytes byte-identical for core-bundle.js, main.html and
cryptogzip.js. Live Chromium on v4.6.159: write_file with object content wrote 27 chars
of readable JSON (not "[object Object]"), read_file with offset:"0"/limit:"200" coerced
to numbers, user_set with key 12345 -> "12345" and object value -> JSON, and the boot
log now carries 0 SafeRegister warnings (52 messages, 0 JS errors) with SimpleGUIModule
registered.

4 files changed, 141 insertions, 17 deletions

diff --git a/modules/core/core-bundle.js b/modules/core/core-bundle.js
index 69b5e1a..b365fa0 100644
--- a/modules/core/core-bundle.js
+++ b/modules/core/core-bundle.js
@@ -4080,14 +4080,15 @@ Only output XML function calls for tool tasks. If no tool is needed, answer norm
                 // bump LATEST_VER + main.html ?v=, re-run admin/scripts/probe-ui-modes.py.
                 // Tracked in .hermes/plans/2026-11-09_*-newos4-ui-rollback.md
                 // this._safeRegister('UIShellModule', 'UI shell');
-                // v4.5.47: Critical ext modules promoted to boot path
-                this._safeRegister('EditorModule', 'editor');
-                this._safeRegister('ShellModule', 'shell');
-                this._safeRegister('AliasModule', 'aliases');
-                this._safeRegister('FinderModule', 'finder');
-                this._safeRegister('FileManagerModule', 'file manager');
-                this._safeRegister('DiffModule', 'diff');
-                this._safeRegister('BusyBoxModule', 'busybox');
+                // v4.5.47 used to _safeRegister() seven critical ext classes here (EditorModule,
+                // ShellModule, AliasModule, FinderModule, FileManagerModule, DiffModule,
+                // BusyBoxModule). They are declared in modules/ext/critical-ext-bundle.js, which is
+                // a <script> AFTER module-loader.js — i.e. it does not exist yet when
+                // `new WebX11Terminal()` runs, so every one of those calls was a guaranteed no-op
+                // that only emitted "[SafeRegister] Skipped … is not in the registry map" on each
+                // page load (adding them to the registry map would still resolve to undefined).
+                // critical-ext-bundle.js owns them and registers each one itself on load.
+                // Do NOT re-add them here — that just restores the warnings.
             }
             _initRegisteredModules() {
                 for (const [name, mod] of Object.entries(this.moduleManager.modules)) {
@@ -4127,6 +4128,7 @@ Only output XML function calls for tool tasks. If no tool is needed, answer norm
                     DiffModule: typeof DiffModule !== 'undefined' ? DiffModule : undefined,
                     BusyBoxModule: typeof BusyBoxModule !== 'undefined' ? BusyBoxModule : undefined,
                     SmartContextModule: typeof SmartContextModule !== 'undefined' ? SmartContextModule : undefined,
+                    SimpleGUIModule: typeof SimpleGUIModule !== 'undefined' ? SimpleGUIModule : undefined,
                     DebugSupervisorModule: typeof DebugSupervisorModule !== 'undefined' ? DebugSupervisorModule : undefined,
                     UIShellModule: typeof UIShellModule !== 'undefined' ? UIShellModule : undefined,
                     BillingModule: typeof BillingModule !== 'undefined' ? BillingModule : undefined,
@@ -10518,6 +10520,54 @@ max_chars: { type: 'integer', description: 'Max characters of page content to re
             _pathArg(v) {
                 return typeof v === 'string' ? v : (v == null ? '' : String(v));
             }
+            // Single boundary coercion for tool arguments. The schemas already say
+            // which args are strings, but models send numbers/arrays/objects anyway
+            // and a handler's `a.field || ''` only catches FALSY values — so
+            // `.trim()`/`.split()`/`.replace()` on a truthy number or object threw a
+            // TypeError and the call was lost (one filed auto-report per tool).
+            // Coerce once here, per declared schema type, instead of patching ~26
+            // handlers. Never throws: an unknown tool, bad defs or a non-object
+            // argument all fall back to the original value.
+            _coerceToolArgs(name, a) {
+                try {
+                    if (!a || typeof a !== 'object' || Array.isArray(a)) return a;
+                    var defs = this._toolDefs;
+                    if (!defs) { defs = this._buildToolDefs(); this._toolDefs = defs; }
+                    if (!Array.isArray(defs)) return a;
+                    var props = null;
+                    for (var i = 0; i < defs.length; i++) {
+                        var fn = defs[i] && defs[i].function;
+                        if (fn && fn.name === name) {
+                            props = (fn.parameters && fn.parameters.properties) || null;
+                            break;
+                        }
+                    }
+                    if (!props) return a;
+                    for (var p in props) {
+                        if (!Object.prototype.hasOwnProperty.call(a, p)) continue;
+                        var v = a[p];
+                        // Absent/null stays absent: _pathArg and the handlers' own
+                        // defaults still own "no value given".
+                        if (v === null || v === undefined) continue;
+                        var type = props[p] && props[p].type;
+                        if (type === 'string') {
+                            if (typeof v === 'string') continue;
+                            if (typeof v === 'number' || typeof v === 'boolean') {
+                                a[p] = String(v);
+                            } else if (typeof v === 'object') {
+                                // Structured content must reach the file as readable
+                                // JSON, never "[object Object]".
+                                try { a[p] = JSON.stringify(v); } catch (_e) { a[p] = String(v); }
+                            }
+                        } else if (type === 'integer' || type === 'number') {
+                            // Only convert unambiguous numeric strings; anything else
+                            // is left for the handler to validate/report.
+                            if (typeof v === 'string' && /^-?\d+(\.\d+)?$/.test(v)) a[p] = Number(v);
+                        }
+                    }
+                    return a;
+                } catch (_e) { return a; }
+            }
             _updateDebugPanel() {
                 if (!this._debugPanelEnabled) return;
                 const panel = document.getElementById('debug-ai-panel');
@@ -11538,6 +11588,13 @@ max_chars: { type: 'integer', description: 'Max characters of page content to re
                         this.terminal.print(`🟡 GUARDRAIL WARNING: ${guardrail.description} (rule: ${guardrail.id})`, 'warning');
                     }
                     a = typeof argsStr === 'object' ? argsStr : (argsStr ? JSON.parse(argsStr) : {});
+                    // A body of "null" / "[1,2]" parses to a non-object, and every
+                    // handler below reads a.field — normalise that once here.
+                    if (!a || typeof a !== 'object' || Array.isArray(a)) a = {};
+                    // ONE schema-driven coercion for the whole switch: a model that
+                    // sends a number/array/object for a schema-string field must not
+                    // reach `.trim()`/`.split()` still holding that type.
+                    a = this._coerceToolArgs(name, a);
                     switch (name) {
                         case 'list_files': {
                             const originalPath = this._pathArg(a.path);
@@ -12448,6 +12505,11 @@ max_chars: { type: 'integer', description: 'Max characters of page content to re
                 let a = {};
                 try {
                     a = typeof argsStr === 'object' ? argsStr : (argsStr ? JSON.parse(argsStr) : {});
+                    if (!a || typeof a !== 'object' || Array.isArray(a)) a = {};
+                    // Same single boundary as runTool: module tools take a string
+                    // `name`/`code`/`file` too and are reachable directly and via
+                    // runTool's `case 'view_module':` delegation.
+                    a = this._coerceToolArgs(name, a);
                     switch (name) {
                     case 'view_module': {
                         const modName = a.name || '';
diff --git a/modules/core/module-aiassist.js b/modules/core/module-aiassist.js
index fb4329f..a9b8fcc 100644
--- a/modules/core/module-aiassist.js
+++ b/modules/core/module-aiassist.js
@@ -1573,6 +1573,54 @@ max_chars: { type: 'integer', description: 'Max characters of page content to re
             _pathArg(v) {
                 return typeof v === 'string' ? v : (v == null ? '' : String(v));
             }
+            // Single boundary coercion for tool arguments. The schemas already say
+            // which args are strings, but models send numbers/arrays/objects anyway
+            // and a handler's `a.field || ''` only catches FALSY values — so
+            // `.trim()`/`.split()`/`.replace()` on a truthy number or object threw a
+            // TypeError and the call was lost (one filed auto-report per tool).
+            // Coerce once here, per declared schema type, instead of patching ~26
+            // handlers. Never throws: an unknown tool, bad defs or a non-object
+            // argument all fall back to the original value.
+            _coerceToolArgs(name, a) {
+                try {
+                    if (!a || typeof a !== 'object' || Array.isArray(a)) return a;
+                    var defs = this._toolDefs;
+                    if (!defs) { defs = this._buildToolDefs(); this._toolDefs = defs; }
+                    if (!Array.isArray(defs)) return a;
+                    var props = null;
+                    for (var i = 0; i < defs.length; i++) {
+                        var fn = defs[i] && defs[i].function;
+                        if (fn && fn.name === name) {
+                            props = (fn.parameters && fn.parameters.properties) || null;
+                            break;
+                        }
+                    }
+                    if (!props) return a;
+                    for (var p in props) {
+                        if (!Object.prototype.hasOwnProperty.call(a, p)) continue;
+                        var v = a[p];
+                        // Absent/null stays absent: _pathArg and the handlers' own
+                        // defaults still own "no value given".
+                        if (v === null || v === undefined) continue;
+                        var type = props[p] && props[p].type;
+                        if (type === 'string') {
+                            if (typeof v === 'string') continue;
+                            if (typeof v === 'number' || typeof v === 'boolean') {
+                                a[p] = String(v);
+                            } else if (typeof v === 'object') {
+                                // Structured content must reach the file as readable
+                                // JSON, never "[object Object]".
+                                try { a[p] = JSON.stringify(v); } catch (_e) { a[p] = String(v); }
+                            }
+                        } else if (type === 'integer' || type === 'number') {
+                            // Only convert unambiguous numeric strings; anything else
+                            // is left for the handler to validate/report.
+                            if (typeof v === 'string' && /^-?\d+(\.\d+)?$/.test(v)) a[p] = Number(v);
+                        }
+                    }
+                    return a;
+                } catch (_e) { return a; }
+            }
             _updateDebugPanel() {
                 if (!this._debugPanelEnabled) return;
                 const panel = document.getElementById('debug-ai-panel');
@@ -2593,6 +2641,13 @@ max_chars: { type: 'integer', description: 'Max characters of page content to re
                         this.terminal.print(`🟡 GUARDRAIL WARNING: ${guardrail.description} (rule: ${guardrail.id})`, 'warning');
                     }
                     a = typeof argsStr === 'object' ? argsStr : (argsStr ? JSON.parse(argsStr) : {});
+                    // A body of "null" / "[1,2]" parses to a non-object, and every
+                    // handler below reads a.field — normalise that once here.
+                    if (!a || typeof a !== 'object' || Array.isArray(a)) a = {};
+                    // ONE schema-driven coercion for the whole switch: a model that
+                    // sends a number/array/object for a schema-string field must not
+                    // reach `.trim()`/`.split()` still holding that type.
+                    a = this._coerceToolArgs(name, a);
                     switch (name) {
                         case 'list_files': {
                             const originalPath = this._pathArg(a.path);
@@ -3503,6 +3558,11 @@ max_chars: { type: 'integer', description: 'Max characters of page content to re
                 let a = {};
                 try {
                     a = typeof argsStr === 'object' ? argsStr : (argsStr ? JSON.parse(argsStr) : {});
+                    if (!a || typeof a !== 'object' || Array.isArray(a)) a = {};
+                    // Same single boundary as runTool: module tools take a string
+                    // `name`/`code`/`file` too and are reachable directly and via
+                    // runTool's `case 'view_module':` delegation.
+                    a = this._coerceToolArgs(name, a);
                     switch (name) {
                     case 'view_module': {
                         const modName = a.name || '';
diff --git a/modules/core/module-loader.js b/modules/core/module-loader.js
index 43c7e06..b926c4a 100644
--- a/modules/core/module-loader.js
+++ b/modules/core/module-loader.js
@@ -4,7 +4,7 @@
     // Core module bundle loaded synchronously in main.html.
     // This loader only handles version cache-busting, splash, terminal init, and optional ext modules.
 
-    const LATEST_VER = 'v4.6.158';
+    const LATEST_VER = 'v4.6.159';
     const CACHE = '?v=' + LATEST_VER;
     // Exposed so ext modules can register their own URL with the same cache-busting version
     // instead of an unversioned path the browser may already have cached (shell.js did).
diff --git a/modules/core/terminal.js b/modules/core/terminal.js
index 91bea4c..d0f6cff 100644
--- a/modules/core/terminal.js
+++ b/modules/core/terminal.js
@@ -1391,14 +1391,15 @@
                 // bump LATEST_VER + main.html ?v=, re-run admin/scripts/probe-ui-modes.py.
                 // Tracked in .hermes/plans/2026-11-09_*-newos4-ui-rollback.md
                 // this._safeRegister('UIShellModule', 'UI shell');
-                // v4.5.47: Critical ext modules promoted to boot path
-                this._safeRegister('EditorModule', 'editor');
-                this._safeRegister('ShellModule', 'shell');
-                this._safeRegister('AliasModule', 'aliases');
-                this._safeRegister('FinderModule', 'finder');
-                this._safeRegister('FileManagerModule', 'file manager');
-                this._safeRegister('DiffModule', 'diff');
-                this._safeRegister('BusyBoxModule', 'busybox');
+                // v4.5.47 used to _safeRegister() seven critical ext classes here (EditorModule,
+                // ShellModule, AliasModule, FinderModule, FileManagerModule, DiffModule,
+                // BusyBoxModule). They are declared in modules/ext/critical-ext-bundle.js, which is
+                // a <script> AFTER module-loader.js — i.e. it does not exist yet when
+                // `new WebX11Terminal()` runs, so every one of those calls was a guaranteed no-op
+                // that only emitted "[SafeRegister] Skipped … is not in the registry map" on each
+                // page load (adding them to the registry map would still resolve to undefined).
+                // critical-ext-bundle.js owns them and registers each one itself on load.
+                // Do NOT re-add them here — that just restores the warnings.
             }
             _initRegisteredModules() {
                 for (const [name, mod] of Object.entries(this.moduleManager.modules)) {
@@ -1438,6 +1439,7 @@
                     DiffModule: typeof DiffModule !== 'undefined' ? DiffModule : undefined,
                     BusyBoxModule: typeof BusyBoxModule !== 'undefined' ? BusyBoxModule : undefined,
                     SmartContextModule: typeof SmartContextModule !== 'undefined' ? SmartContextModule : undefined,
+                    SimpleGUIModule: typeof SimpleGUIModule !== 'undefined' ? SimpleGUIModule : undefined,
                     DebugSupervisorModule: typeof DebugSupervisorModule !== 'undefined' ? DebugSupervisorModule : undefined,
                     UIShellModule: typeof UIShellModule !== 'undefined' ? UIShellModule : undefined,
                     BillingModule: typeof BillingModule !== 'undefined' ? BillingModule : undefined,