Fix tunnel health check

src/lib/tunnel/cloudflared.js

@@ -289,7 +289,7 @@ export async function spawnQuickTunnel(localPort, onUrlUpdate) {
 
   const requestedProtocol = String(process.env.TUNNEL_TRANSPORT_PROTOCOL || process.env.CLOUDFLARED_PROTOCOL || DEFAULT_QUICK_TUNNEL_PROTOCOL).trim().toLowerCase();
   const tunnelProtocol = QUICK_TUNNEL_PROTOCOLS.has(requestedProtocol) ? requestedProtocol : DEFAULT_QUICK_TUNNEL_PROTOCOL;
-  const child = spawn(binaryPath, ["tunnel", "--url", `http://127.0.0.1:${localPort}`, "--config", configPath, "--no-autoupdate"], {
+  const child = spawn(binaryPath, ["tunnel", "--url", `http://127.0.0.1:${localPort}`, "--config", configPath, "--no-autoupdate", "--retries", "99"], {
     detached: false,
     windowsHide: true,
     cwd: os.tmpdir(),

src/lib/tunnel/tunnelConfig.js

@@ -12,7 +12,7 @@ export const INTERNET_CHECK = {
   timeoutMs: 3000,
 };
 
-export const RESTART_COOLDOWN_MS = 180000;
+export const RESTART_COOLDOWN_MS = 120000;
 export const NETWORK_SETTLE_MS = 2500;
 export const WATCHDOG_INTERVAL_MS = 60000;
 export const NETWORK_CHECK_INTERVAL_MS = 5000;

src/lib/tunnel/tunnelManager.js

@@ -31,6 +31,10 @@ export function isTunnelManuallyDisabled() { return tunnelSvc.cancelToken.cancel
 export function isTunnelReconnecting() { return tunnelSvc.spawnInProgress; }
 export function isTailscaleReconnecting() { return tailscaleSvc.spawnInProgress; }
 
+// Callback invoked when cloudflared exits unexpectedly (set by initializeApp)
+let onTunnelUnexpectedExit = null;
+export function setTunnelUnexpectedExitCallback(cb) { onTunnelUnexpectedExit = cb; }
+
 // ─── Cloudflare Tunnel ───────────────────────────────────────────────────────
 
 async function registerTunnelUrl(shortId, tunnelUrl) {
@@ -55,10 +59,18 @@ export async function enableTunnel(localPort = 20128) {
   try {
     if (isCloudflaredRunning()) {
       const existing = loadState();
-      if (existing?.tunnelUrl && await probeUrlAlive(existing.tunnelUrl)) {
+      if (existing?.tunnelUrl && existing?.shortId) {
         const publicUrl = `https://r${existing.shortId}.abc-tunnel.us`;
-        console.log(`[Tunnel] already running, reuse: ${existing.tunnelUrl}`);
-        return { success: true, tunnelUrl: existing.tunnelUrl, shortId: existing.shortId, publicUrl, alreadyRunning: true };
+        // Reuse only if BOTH direct + public URL alive (avoid stale socket after network change)
+        const [directOk, publicOk] = await Promise.all([
+          probeUrlAlive(existing.tunnelUrl),
+          probeUrlAlive(publicUrl),
+        ]);
+        if (directOk && publicOk) {
+          console.log(`[Tunnel] already running, reuse: ${existing.tunnelUrl}`);
+          return { success: true, tunnelUrl: existing.tunnelUrl, shortId: existing.shortId, publicUrl, alreadyRunning: true };
+        }
+        console.log(`[Tunnel] stale (direct=${directOk} public=${publicOk}), respawn`);
       }
     }
 
@@ -77,6 +89,12 @@ export async function enableTunnel(localPort = 20128) {
       await updateSettings({ tunnelEnabled: true, tunnelUrl: url });
     };
 
+    // Register exit handler BEFORE spawn so it fires even on early exit
+    setUnexpectedExitHandler(() => {
+      console.warn("[Tunnel] cloudflared exited unexpectedly, scheduling respawn");
+      if (onTunnelUnexpectedExit) onTunnelUnexpectedExit();
+    });
+
     const { tunnelUrl } = await spawnQuickTunnel(localPort, onUrlUpdate);
     console.log(`[Tunnel] spawned: ${tunnelUrl}`);
     throwIfCancelled(token, "tunnel");