[jleonar2]

Problem

In the standalone production build, webpack creates two separate copies of modelDeprecation.ts:

• Module 498996 (chunk 73671): hydrated by the startup path (applyRuntimeSettings) — used for request routing
• Module 32041 (chunk 33364): used by GET /api/settings/model-aliases — starts empty after each restart

Each module instance has its own _customAliases state. The startup code hydrates module 498996 from the DB, but the API route reads from module 32041 which was never initialized. This causes the Settings → Routing UI to show "No exact-match aliases configured" even though the aliases are persisted in the DB and work fine for request routing.

Verification (before fix, after restart):

Check	Result
GET /api/settings → modelAliases	✅ present (reads directly from DB)
GET /api/settings/model-aliases → custom	❌ {} (reads from empty in-memory state)
DB key_value row	✅ data intact

Fix

The GET handler in /api/settings/model-aliases now detects an empty _customAliases state and reads the modelAliases key from the settings blob in the DB, calling setCustomAliases() to hydrate this module instance. This is a best-effort fallback — when _customAliases is already populated (e.g. dev mode where only one module instance exists), no DB read occurs.

~15 lines changed in route.ts.

Regression test

tests/unit/model-aliases-settings-route-selfheal.test.ts — 3/3 passing:

1. Hydrates from DB when in-memory state is empty
2. Skips hydration when in-memory state is already populated (no overwrite)
3. Handles missing modelAliases in DB gracefully

Live verification

After restart with the fix applied:

curl -s http://localhost:20128/api/settings/model-aliases | jq .custom
# Returns stored aliases instead of {}

[gemini-code-assist]

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