fix: harden synced registry and keepalive helpers

.github/scripts/__tests__/capability-bundle-contract.test.js

@@ -205,6 +205,25 @@ test('keepalive metrics carry applied bundle metadata and rejection reasons', ()
   assert.deepEqual(record.capability_rejection_reasons, ['repo']);
 });
 
+test('keepalive metrics ignore malformed capability bundle entries', () => {
+  const record = buildMetricsRecord({
+    prNumber: 123,
+    iteration: 2,
+    action: 'run',
+    errorCategory: 'none',
+    durationMs: 10,
+    tasksTotal: 3,
+    tasksComplete: 1,
+    capabilityBundles: {
+      applied: [null, 'invalid', [], { capability_id: 'keepalive/static-spa' }],
+      rejected: [null, 'invalid', [], { reason: 'repo' }],
+    },
+  });
+
+  assert.deepEqual(record.capability_bundle_ids, ['keepalive/static-spa']);
+  assert.deepEqual(record.capability_rejection_reasons, ['repo']);
+});
+
 test('capability bundle metrics input parser preserves applied and rejected arrays', () => {
   const parsed = parseCapabilityBundlesInput(JSON.stringify({
     applied: [{ capability_id: 'keepalive/static-spa' }],

.github/scripts/keepalive_loop.js

@@ -801,8 +801,12 @@ function buildMetricsRecord({
   const capabilityResult = capabilityBundles && typeof capabilityBundles === 'object'
     ? capabilityBundles
     : { applied: [], rejected: [] };
-  const applied = Array.isArray(capabilityResult.applied) ? capabilityResult.applied : [];
-  const rejected = Array.isArray(capabilityResult.rejected) ? capabilityResult.rejected : [];
+  const applied = Array.isArray(capabilityResult.applied)
+    ? capabilityResult.applied.filter((bundle) => bundle && typeof bundle === 'object' && !Array.isArray(bundle))
+    : [];
+  const rejected = Array.isArray(capabilityResult.rejected)
+    ? capabilityResult.rejected.filter((bundle) => bundle && typeof bundle === 'object' && !Array.isArray(bundle))
+    : [];
   return {
     pr_number: toNumber(prNumber, 0),
     iteration: Math.max(1, toNumber(iteration, 0)),

tests/tools/test_llm_registry_selection.py

@@ -246,6 +246,23 @@ def test_bundled_stale_slot_pin_uses_reviewed_registry_selection(
     ]
 
 
+def test_bundled_stale_slot_pin_is_debug_only(
+    monkeypatch: pytest.MonkeyPatch, tmp_path: Path, caplog: pytest.LogCaptureFixture
+) -> None:
+    registry_path = tmp_path / "registry.json"
+    slots_path = tmp_path / "slots.json"
+    _write_registry(registry_path)
+    _write_slots(slots_path, model="retired-model", profile="")
+    monkeypatch.setenv(registry.ENV_MODEL_REGISTRY_CONFIG, str(registry_path))
+    monkeypatch.delenv(registry.ENV_SLOT_CONFIG, raising=False)
+    monkeypatch.setattr(registry, "DEFAULT_SLOT_CONFIG_PATH", slots_path)
+
+    with caplog.at_level("WARNING"):
+        registry.load_slot_config()
+
+    assert "Skipping unresolved slot model pin" not in caplog.text
+
+
 def test_noncurrent_selected_model_fails_closed(
     monkeypatch: pytest.MonkeyPatch, tmp_path: Path
 ) -> None:

tools/llm_registry.py

@@ -357,18 +357,25 @@ def load_slot_config(*, github_default_model: str = "") -> list[SlotDefinition]:
         ):
             model = explicit_model
         elif provider and explicit_model and explicit_model != model:
-            logger.warning(
-                "Skipping unresolved slot model pin %s/%s; reviewed %s selection is %s",
-                provider,
-                explicit_model,
-                profile,
-                model or "unavailable",
-            )
             # A caller-supplied slot file is an allowlist and must fail closed.
             # The repository's bundled legacy file is advisory: ignore a stale
             # pin and retain the reviewed registry selection for that provider.
             if os.environ.get(ENV_SLOT_CONFIG):
+                logger.warning(
+                    "Skipping unresolved slot model pin %s/%s; reviewed %s selection is %s",
+                    provider,
+                    explicit_model,
+                    profile,
+                    model or "unavailable",
+                )
                 continue
+            logger.debug(
+                "Ignoring advisory bundled slot model pin %s/%s; reviewed %s selection is %s",
+                provider,
+                explicit_model,
+                profile,
+                model or "unavailable",
+            )
         if provider and configured_profile and not model:
             logger.warning(
                 "Skipping slot with unresolved reviewed profile: %s/%s",