§B: port stability fixes from 0.3.x onto the clean base

Ported only the fixes that actually apply to the pre-refactor base
(the handshake fixes 6eb7b36/d65af35 fix bugs the 0.3.1 multi-server
refactor introduced into the new outbounds/ostp.rs; the base bridge.rs
already waits for the handshake response with retransmit + NAT64
fallback, so they are intentionally skipped).

- EMFILE (922cf0b): rlimit::increase_nofile_limit at CLI startup.
- Logs (1151726): UoT connect/disconnect → debug; rate-limit the
  unauthorized-probe log to one line / ~30s so a junk/probe flood can't
  spam the log (and a client running junk-over-UDP can't self-ban).
- Helper lifecycle + bypass routes (b6e78c1):
  * ostp-tun-helper forces std::process::exit(0) after run_server so the
    WinTun adapter and its metric-0 default route are reclaimed instead
    of lingering as a zombie that breaks the next connect.
  * windows_route: delete_routes_for_dest() purges stale /32s, dedupe
    bypass IPs, and log add failures at warn!.
  * windows: retry tun::create through the transient ERROR_INVALID_
    PARAMETER window and widen the adapter-index lookup to ~15s.

Co-Authored-By: Claude Opus 4.8 <noreply@anthropic.com>

Cargo.lock

@@ -1395,6 +1395,7 @@ dependencies = [
  "ostp-core",
  "ostp-server",
  "rand 0.8.5",
+ "rlimit",
  "serde",
  "serde_json",
  "tokio",
@@ -1853,6 +1854,15 @@ dependencies = [
  "windows-sys 0.52.0",
 ]
 
+[[package]]
+name = "rlimit"
+version = "0.11.0"
+source = "registry+https://github.com/rust-lang/crates.io-index"
+checksum = "f35ee2729c56bb610f6dba436bf78135f728b7373bdffae2ec815b2d3eb98cc3"
+dependencies = [
+ "libc",
+]
+
 [[package]]
 name = "rust-embed"
 version = "8.11.0"

ostp-server/src/lib.rs

@@ -285,6 +285,10 @@ pub async fn run_server(
 
     // Headless event logger
     tokio::spawn(async move {
+        // Rate-limit unauthorized-probe logging so a junk/probe flood can't spam the log
+        // (and so a client running junk-over-UDP can't trigger a self-ban via log noise).
+        let mut probe_window_start: Option<Instant> = None;
+        let mut probe_suppressed: u64 = 0;
         while let Some(ev) = ui_event_rx.recv().await {
             match ev {
                 UiEvent::Log(msg) => {
@@ -303,7 +307,23 @@ pub async fn run_server(
                 }
                 UiEvent::UnauthorizedProbe { peer, bytes } => {
                     if debug {
-                        tracing::debug!("Unauthorized probe from {peer} ({bytes} bytes)");
+                        let now = Instant::now();
+                        let elapsed = probe_window_start
+                            .map(|s| now.duration_since(s))
+                            .unwrap_or(Duration::MAX);
+                        if elapsed >= Duration::from_secs(30) {
+                            if probe_suppressed > 0 {
+                                tracing::debug!(
+                                    "(+{} more unauthorized probes suppressed in the previous ~30s)",
+                                    probe_suppressed
+                                );
+                            }
+                            probe_window_start = Some(now);
+                            probe_suppressed = 0;
+                            tracing::debug!("Unauthorized probe from {peer} ({bytes} bytes)");
+                        } else {
+                            probe_suppressed += 1;
+                        }
                     }
                 }
                 UiEvent::PeerSeen { .. } => {}

ostp-server/src/transport/uot.rs

@@ -5,7 +5,6 @@ use std::net::SocketAddr;
 use std::sync::Arc;
 use tokio::io::{AsyncReadExt, AsyncWriteExt};
 use tokio::sync::{mpsc, RwLock};
-use tracing::info;
 
 pub async fn handle_tcp_connection<S>(
     stream: S,
@@ -16,7 +15,7 @@ pub async fn handle_tcp_connection<S>(
 where
     S: tokio::io::AsyncRead + tokio::io::AsyncWrite + Unpin + Send + 'static,
 {
-    info!("UoT client connected from {}", peer_addr);
+    tracing::debug!("UoT client connected from {}", peer_addr);
 
     // Register this connection in the map
     let (tx, mut rx) = mpsc::channel::<Bytes>(16384);
@@ -54,6 +53,6 @@ where
     });
 
     let _ = tokio::join!(writer_task, reader_task);
-    info!("UoT client disconnected: {}", peer_addr);
+    tracing::debug!("UoT client disconnected: {}", peer_addr);
     Ok(())
 }

ostp-tun-helper/src/main.rs

@@ -88,7 +88,19 @@ async fn main() -> Result<()> {
         log_to_file(&format!("Fatal error: {}", e));
     }
     log_to_file("Helper exiting");
-    Ok(())
+
+    // The WinTun blocking `receive` runs on a thread that `task.abort()` cannot
+    // cancel, so it keeps the adapter handle — and the default route bound to it —
+    // alive and prevents the tokio runtime from shutting down. Without this the
+    // process lingers as a zombie: `ostp_tun` stays Up, its metric-0 default route
+    // competes with the physical one, and the NEXT connect fails to install the
+    // server bypass route, so traffic loops back into a dead tunnel (no internet).
+    // The GUI launches a fresh helper for every connect, so this process has no
+    // more work once run_server returns. Give the synchronous route/firewall
+    // teardown a moment to finish, then force the process to exit so the kernel
+    // reclaims the adapter and every route bound to it. (Ported from 0.3.x b6e78c1.)
+    tokio::time::sleep(Duration::from_millis(800)).await;
+    std::process::exit(0);
 }
 
 async fn run_server(expected_token: String, port: u16) -> Result<()> {

ostp-tun/src/windows.rs

@@ -72,32 +72,59 @@ pub async fn create(opts: OstpTunOptions) -> Result<OstpTunInterface> {
         .mtu(opts.mtu)
         .up();
 
-    let dev = tun::create(&tun_cfg).map_err(|e| anyhow!("Failed to create TUN device: {}", e))?;
+    // The IpHelper calls the `tun` crate performs right after Adapter::create
+    // (set address / mtu) can transiently fail with ERROR_INVALID_PARAMETER
+    // (os error 87) when the freshly created interface is not yet registered
+    // in the IP stack. Retry a few times; on retry the crate reuses the
+    // existing adapter via Adapter::open. (Ported from 0.3.x b6e78c1.)
+    let dev = {
+        let mut attempt = 0;
+        loop {
+            attempt += 1;
+            match tun::create(&tun_cfg) {
+                Ok(d) => break d,
+                Err(e) if attempt < 5 => {
+                    tracing::warn!(
+                        "TUN device creation attempt {}/5 failed: {} — retrying in 300ms",
+                        attempt, e
+                    );
+                    tokio::time::sleep(std::time::Duration::from_millis(300)).await;
+                }
+                Err(e) => return Err(anyhow!("Failed to create TUN device after {} attempts: {}", attempt, e)),
+            }
+        }
+    };
     let dev = tun::AsyncDevice::new(dev).map_err(|e| anyhow!("TUN device async failed: {}", e))?;
     tracing::info!("TUN device 'ostp_tun' created.");
 
     let current_exe = std::env::current_exe()?.to_string_lossy().into_owned();
 
+    // A freshly created WinTun adapter can take several seconds to appear in
+    // GetAdaptersAddresses (it only shows up once it has an operational IPv4
+    // binding). The default route via the TUN is what actually captures
+    // traffic, so this lookup is critical — give it a generous window (~15s).
     let mut tun_index = None;
-    for _ in 0..20 {
+    for _ in 0..75 {
         if let Some(idx) = windows_route::sys::get_interface_index("ostp_tun") {
             tun_index = Some(idx);
             break;
         }
-        tokio::time::sleep(std::time::Duration::from_millis(100)).await;
+        tokio::time::sleep(std::time::Duration::from_millis(200)).await;
     }
 
     if let Some(idx) = tun_index {
-        let _ = windows_route::sys::add_ipv4_route(
+        match windows_route::sys::add_ipv4_route(
             std::net::Ipv4Addr::new(0, 0, 0, 0),
             std::net::Ipv4Addr::new(0, 0, 0, 0),
             std::net::Ipv4Addr::new(10, 1, 0, 1),
             idx,
             5,
-        );
-        tracing::info!("Default route via TUN (if_index={idx}, metric=5) added.");
+        ) {
+            Ok(()) => tracing::info!("Default route via TUN (if_index={idx}, metric=5) added."),
+            Err(e) => tracing::error!("Failed to add default route via TUN (if_index={idx}): {e} — traffic will NOT be captured."),
+        }
     } else {
-        tracing::warn!("Could not find ostp_tun index in routing table — traffic may not be captured.");
+        tracing::error!("Could not find ostp_tun index in routing table after 15s — traffic will NOT be captured.");
     }
 
     let exe1 = current_exe.clone();

ostp-tun/src/windows_route.rs

@@ -168,6 +168,34 @@ pub mod sys {
         }
     }
 
+    /// Delete every routing-table entry whose destination is `dest`/`mask`,
+    /// regardless of its gateway or interface. Used to purge stale bypass routes
+    /// left by a previous session (possibly pointing at an old gateway after a
+    /// network change) so a fresh, correct one can be installed. (Ported from 0.3.x b6e78c1.)
+    pub fn delete_routes_for_dest(dest: Ipv4Addr, mask: Ipv4Addr) {
+        unsafe {
+            let mut size: ULONG = 0;
+            if GetIpForwardTable(ptr::null_mut(), &mut size, 0) != ERROR_INSUFFICIENT_BUFFER {
+                return;
+            }
+            let mut buf: Vec<u8> = vec![0; size as usize];
+            let table = buf.as_mut_ptr() as *mut MIB_IPFORWARDTABLE;
+            if GetIpForwardTable(table, &mut size, 0) != NO_ERROR {
+                return;
+            }
+            let want_dest = ipv4_to_dword(dest);
+            let want_mask = ipv4_to_dword(mask);
+            let entries =
+                std::slice::from_raw_parts_mut((*table).table.as_mut_ptr(), (*table).dwNumEntries as usize);
+            for row in entries {
+                if row.dwForwardDest == want_dest && row.dwForwardMask == want_mask {
+                    // Delete the exact existing row (its own nexthop/ifindex).
+                    let _ = DeleteIpForwardEntry(row);
+                }
+            }
+        }
+    }
+
     /// Add bypass routes for a list of resolved IP addresses (typically from exclusion config).
     /// Each IP gets a /32 host route via the physical gateway so it bypasses the TUN.
     /// Returns list of (ip, gw, if_index) that were successfully added, for later cleanup.
@@ -178,15 +206,24 @@ pub mod sys {
         metric: u32,
     ) -> Vec<(Ipv4Addr, Ipv4Addr, u32)> {
         let mut added = Vec::new();
+        let mut seen = std::collections::HashSet::new();
+        let mask = Ipv4Addr::new(255, 255, 255, 255);
         for &ip in ips {
-            let mask = Ipv4Addr::new(255, 255, 255, 255);
+            // The server IP is passed both as server_ip and inside bypass_ips, so
+            // dedupe to avoid a guaranteed "already exists" failure on the second add.
+            if !seen.insert(ip) {
+                continue;
+            }
+            // Purge any pre-existing /32 for this dest (e.g. a stale route via an
+            // old gateway from a previous session) so add_ipv4_route below installs
+            // the correct one instead of failing with ERROR_OBJECT_ALREADY_EXISTS.
+            delete_routes_for_dest(ip, mask);
             match add_ipv4_route(ip, mask, gw, if_index, metric) {
                 Ok(()) => {
                     added.push((ip, gw, if_index));
                 }
                 Err(e) => {
-                    // 87 = ERROR_INVALID_PARAMETER (route may already exist)
-                    tracing::debug!("bypass route add {ip}/32 via {gw}: {e}");
+                    tracing::warn!("bypass route add {ip}/32 via {gw} (if {if_index}) failed: {e}");
                 }
             }
         }

ostp/Cargo.toml

@@ -20,3 +20,4 @@ tracing.workspace = true
 tracing-subscriber = { version = "0.3", features = ["env-filter"] }
 ostp-core = { path = "../ostp-core" }
 colored = "2.1"
+rlimit = "0.11.0"

ostp/src/main.rs

@@ -363,6 +363,10 @@ struct MuxConfig {
 
 #[tokio::main]
 async fn main() -> Result<()> {
+    // Raise the open-file-descriptor limit to avoid EMFILE under many concurrent
+    // connections (ported from 0.3.x fix 922cf0b). No-op / best-effort on platforms
+    // where it does not apply.
+    let _ = rlimit::increase_nofile_limit(1048576);
     ostp_client::logging::setup_panic_hook();
     let _log_guard = ostp_client::logging::init_tracing("info", "ostp-cli", env!("CARGO_PKG_VERSION"));