Merge pull request 'Auto-refuel on leg start; all manual refueling UI + endpoint removed (ISS-082, v0.42.0)' (#86) from feat/auto-refuel into master

Auto-refuel on leg start; manual refueling removed (ISS-082, v0.42.0)

CHANGELOG.md

@@ -1,5 +1,33 @@
 # Changelog
 
+## v0.42.0 — 2026-09-21 15:02
+- **Auto-refuel on dispatch (ISS-082).** Manual refueling is gone — planes top up automatically at dispatch, so a grounded plane can always start any leg that fits a full tank when cash allows. `flyPlane` (`lib/game/actions.ts`) tops the tank to `min(maxFuel, max(fuel, 1.5 × required))` before departure — the same target/price terms as the removed forFlight mode: liters × FUEL_PRICE_PER_L minus the rep-scaled discount (v0.38.0), deducted from cash; unaffordable → 409 `insufficient funds` with nothing mutated, and a leg that doesn't fit even a full tank still 409s `insufficient fuel` (the backstop). The engine's auto-chain (`deliverPackages`, `lib/sim/engine.ts`) does the same at landing: when the next queued leg exceeds the landed fuel it tops up to the identical target when cash allows and chains anyway — only an unaffordable top-up grounds the plane with the queue kept intact
+- **REMOVED** `POST /api/planes/:planeId/refuel` (route + route tests), the `refuelPlane()` action + `RefuelOptions` (`lib/game/actions.ts`), the left-pane "Refuel to full" section and per-leg Refuel button with their dead state/derived values (`components/LeftPane.tsx`), and the OpenAPI `/api/planes/{planeId}/refuel` path + `RefuelRequest` schema — endpoint count 14 → 13, stale refuel mentions reworded in info/state/queue/repair descriptions, and fly's description + 409 now document the auto-refuel
+- **Test hook.** New POST `/api/test/set-fuel` (`FLIGHT_TEST_HOOKS=1` only): `{ planeId, fuel }` forces a plane's fuel — finite number in [0, maxFuel] (400 outside / unknown field), 404 unknown plane; sibling of set-health
+- **Tests.** Unit: `refuelPlane` suite deleted; new `flyPlane` auto-refuel tests (exact top-up target + rep-discounted cost at rep 30, free no-op on a full tank, cash 0 → 409 insufficient funds with fuel unchanged, UNNT→LPPD backstop still 409s); the broken-burn test reworked to pin that ×1.5 burn raises the top-up target; `engine.test.ts`'s chain test flipped — a short tank now chains via an affordable top-up (post-top-up fuel + exact cost from the real helpers) plus a new cash-0 variant grounding with the queue intact. E2E: every `/refuel` setup/retry site (~25 across 9 specs) replaced by the set-fuel hook, heal helpers drop their refuel-and-retry guard (dispatch auto-refuels), right-pane's per-leg Refuel test and two-planes' "refuel section lists both planes" deleted in favor of one new end-to-end dispatch auto-top-up test (set-fuel drops fuel to 500 L → fly → exact cash delta from snapshot + real helpers, landed fuel = weighted burn from the topped start value), panes.spec.ts now asserts Refuel-UI absence in both panes, api.spec.ts pins thirteen endpoints
+
+## v0.41.0 — 2026-09-21 13:26
+- **Queue UI fixes (ISS-077).** Three queue-related map/UI fixes, no server logic changed:
+  - **Would-409 controls are disabled.** The on-board "Fly to …" button (`components/LeftPane.tsx`) is additionally disabled while the plane is flying and its destination is already active or queued (title "Already in flight queue"); the Relocate section disables its GO button for the same reason AND renders the selected plane's active/queued airports as native disabled `<option>`s. Grounded planes are untouched — their clicks go to `/fly`, which has no such conflict
+  - **Hover trace starts at the landing airport.** Hovering an on-board package while its carrier is FLYING now traces from the carrier's LANDING airport (`destIcao`), not its live mid-flight position (`components/Map.tsx`) — the hover previews what happens AFTER this leg lands; the solid active-leg + dotted queue layers already show where it is. Grounded / no-active-leg carriers keep today's behavior exactly (live position = the plane's airport). `hoverTraceGeoJson` returns an empty collection when start == dest, so a package destined for the active leg's destination draws nothing there — the solid layer covers it
+  - **Grounded queues draw dotted lines.** `queuedRoutesGeoJson` (`lib/mapData.ts`) now also draws GROUNDED ('available') planes with a non-empty queue, chaining from their current airport (`locationIcao → queue[0] → …`); flying planes keep the `[destIcao, ...queue]` chain; 'repairing' planes draw nothing. Same source/layer — no new MapLibre layer
+- **Tests.** Unit: `lib/mapData.test.ts` pins the grounded chain (exact endpoints), the unknown-first-point skip, the repairing skip and the start==dest empty trace; all flying-case pins stay green. E2E: `e2e/hover.spec.ts`'s mid-flight test is reworked — a package destined for a QUEUED stop beyond the active leg, hover traces from the landing airport to that stop with no segment starting at the departure airport (deterministic: paused right after dispatch); new `e2e/queue.spec.ts` test pins the grounded two-leg chain HUB → DEST → QUEUE in the `queue-routes` layer
+
+## v0.40.0 — 2026-09-21 13:06
+- **Top-bar version link (ISS-080).** The header's version tag (`components/Map.tsx`) is now an anchor to the repo's `CHANGELOG.md` on Gitea (`app-version` testid, opens in a new tab); one small CSS rule keeps it subtle against the dark header. E2E: `e2e/map.spec.ts` pins the exact href
+- **On-board ICAO tags (ISS-081).** The on-board package row in the fleet list (`components/LeftPane.tsx`) shows 4-char ICAO tags instead of full airport names — both the route span (new `onboard-route-{id}` testid) and the "Fly to …" button label + title. Other name displays (in-flight leg, plane location, map popup, open-package rows, toasts) are unchanged. E2E: one new assertion in `e2e/actions.spec.ts` pins the ICAO route on a loaded package
+
+## v0.39.0 — 2026-09-21 12:02
+- **Maintenance (ISS-069).** Planes wear out and can be repaired: distance-based health, a broken state that burns more fuel, and a repair action that grounds the plane for 3 sim days. New balance constants in `lib/game/catalog.ts` (all ponytail-tunable): `WEAR_PER_KM = 0.005`, `BROKEN_BURN_MULTIPLIER = 1.5`, `REPAIR_COST = 1_500` (flat), `REPAIR_DURATION_MS = 3 × 86_400_000`, plus the pure helper `conditionBurnMultiplier(health)` — exactly 1 above zero health, ×1.5 at/below it
+- **Schema.** Two new `planes` columns in all four places: Drizzle schema (`lib/db/schema.ts`), raw DDL + guarded `ALTER TABLE … ADD COLUMN` migrations in `migrateColumns()` (pre-existing rows backfill to full health / NULL gate, mirroring the weight_kg/special precedent), and the seed insert path — starter plane in `buildSeed` (`lib/game/seed.ts`) and every `buyPlane` delivery start at `health: 100`. New plane status `'repairing'` added to the three pinned unions (schema enum, `PlaneState`, OpenAPI) plus `mapData.ts`'s feature props
+- **Wear.** At landing only — `deliverPackages` (`lib/sim/engine.ts`) drops health by `WEAR_PER_KM × distanceKm` per landed leg (clamped at 0), in both the grounded and auto-chain write branches. A broken plane is one with `health ≤ 0`: it still flies, but burns ×1.5 more fuel — applied as a third factor alongside wind at ALL FIVE burn sites that hold the plane row: `flyPlane` dispatch feasibility + `refuelPlane` forFlight requirement (`lib/game/actions.ts`), engine landed-fuel + auto-chain next-leg check (`lib/sim/engine.ts`), and the live in-flight gauge in `livePlane()` (`lib/game/state.ts`). The engine's landed fuel uses the PRE-landing health (frozen at departure, like fuel) so it stays bit-consistent with the UI gauge; the chained leg's feasibility uses the post-wear value
+- **Repair.** New action `repairPlane` (`lib/game/actions.ts`) + POST `/api/planes/{planeId}/repair` (no body): 404 unknown plane, 409 not grounded ("only grounded planes can be repaired"), free no-op at full health (mirrors refuel), else charges the flat `REPAIR_COST`, restores health to 100 and grounds the plane in `'repairing'` with a gate at `clockMs + REPAIR_DURATION_MS`. The engine's new `finishRepairs` pass (same shape as `expirePackages`) runs inside every advancing tick — even when nothing landed — flipping gated planes back to `'available'` and clearing the gate. While repairing, the existing `status !== 'available'` guards in load/fly/refuel/sell/abandon block everything automatically
+- **Snapshot & OpenAPI.** `PlaneState` gains `health: number` + `repairUntilSimTime: number | null`; the repair endpoint is documented (200 → snapshot, 404/409). Pins updated in lockstep: `lib/openapi.test.ts` (fourteen endpoints, nine action-endpoint loop with errorCodes `['404','409']`, PlaneState key list) and `e2e/api.spec.ts`
+- **UI.** The fleet rows (`components/LeftPane.tsx`) show an amber health bar (new `.health-bar`, modeled on `.fuel-bar`) + a `{n}%` readout next to the fuel text; grounded planes get a red "broken" pill at zero health and an amber "in repair" pill while the gate runs (`.status-broken` / `.status-repairing`). A Repair button appears for any grounded plane below full health — no cost preview, flat cost is server-side only
+- **Test hook.** POST `/api/test/set-health` (`FLIGHT_TEST_HOOKS=1` only): `{ planeId, health?, repairUntilMs? }` forces a plane's health (finite in [0,100]) and/or sets its repair gate to `clock + repairUntilMs` — lets e2e force the broken state and shorten an active 3-day gate without flying thousands of km
+- **Tests.** New unit tests: wear accumulation per landed leg + clamping at 0 across multiple legs; broken-state ×1.5 landed fuel vs a healthy control on the identical leg; `conditionBurnMultiplier` pins; `flyPlane` feasibility using the adjusted requirement (same tank flyable at full health, 409 when broken); `repairPlane` (exact cost/status/gate/health, free no-op, 409s for flying/repairing/insufficient funds, load/fly/refuel/sell all blocked while repairing) and `finishRepairs` (gate boundary + flip-back through a full `tickOnce` with nothing landed). E2E: new `e2e/maintenance.spec.ts` — the visible flow per the issue (force 42 → UI shows it; force 0 → broken pill + short full-tank leg lands with exactly the ×1.5-adjusted fuel from the real lib helpers; click Repair → exact cash drop + "in repair" pill; shorten the gate via the hook → back to service at health 100), restoring a clean starter on exit
+- **E2E drift mitigation.** Wear accumulates across the whole CI run (one shared DB, workers:1) — the self-heal helpers in `e2e/right-pane.spec.ts` (`flyHomeViaApi`), `e2e/two-planes.spec.ts` (`resetFleet`) and `e2e/actions.spec.ts` (`flyHomeViaApi`) now restore full health + clear any active repair gate first, so the farthest-flyable pickers and the FAR round-trip feasibility pin never see a worn or broken starter
+
 ## v0.38.0 — 2026-09-21 10:47
 - **Reputation economy (ISS-072).** Reputation is no longer a dead stat — it drives the economy through three simple tunable formulas, all built on one new pure helper `repRate(reputation, perPoint, cap)` in `lib/game/catalog.ts` (linear above the starting value of 10, capped; exactly 0 at/below start so default-rep behavior is byte-identical):
   - **Cheaper plane purchases** — `buyPlane` (`lib/game/actions.ts`) charges `price × (1 − repRate(rep, PLANE_DISCOUNT_PER_REP = 0.01, MAX_PLANE_DISCOUNT = 0.4))`, rounded to 2dp; the effective cost drives both the funds check and the deduction (up to 40% off at rep ≥ 50)

PLAN.md

@@ -5,7 +5,7 @@ No manual flying — planes auto-fly assigned routes; you manage the business fr
 
 ## Layout (single screen)
 - Left pane — Assets: fleet list (plane type, status, fuel, location), wallet, reputation
-- Right pane — Jobs & Market: contracts between airports (reward, deadline, cargo/passengers) with accept/dispatch actions; market actions (buy/sell planes, refuel, maintenance)
+- Right pane — Jobs & Market: contracts between airports (reward, deadline, cargo/passengers) with accept/dispatch actions; market actions (buy/sell planes, maintenance). No manual refueling — dispatch auto-tops-up the tank to 150% of the leg requirement (capped at capacity) when cash allows
 - Middle — Map: EU airports as markers, animated plane positions along routes, active contract routes highlighted; click airport → info (runways, local time, weather); click plane → status
 
 ## Core loop

app/api/planes/[planeId]/fly/route.test.ts

@@ -63,17 +63,17 @@ describe('POST /api/planes/:planeId/fly', () => {
       .where(eq(schema.planes.id, 'plane-starter'));
   });
 
-  it('rejects a leg the plane cannot fuel with 409 (burn > fuel)', async () => {
+  it('rejects a leg that does not fit even a full tank with 409 (ISS-082 backstop)', async () => {
     const { db } = await getGameDb();
-    // EDDF → LEMD ≈ 1950 km × 1.75 L/km ≈ 3400 L — far more than 1 L.
+    // UNNT → LPPD ≈ 7670 km needs ~10k L — beyond the ATR's 6300 L tank, so no auto-refuel can make it flyable.
-    await db.update(schema.planes).set({ fuel: 1 }).where(eq(schema.planes.id, 'plane-starter'));
+    await db.update(schema.planes).set({ locationIcao: 'UNNT' }).where(eq(schema.planes.id, 'plane-starter'));
 
-    const res = await post('plane-starter', { destIcao: 'LEMD' });
+    const res = await post('plane-starter', { destIcao: 'LPPD' });
     expect(res.status).toBe(409);
     expect(((await res.json()) as { error: string }).error).toMatch(/insufficient fuel/i);
 
-    // Refill for later tests.
+    // Put the starter back at the hub for later tests.
-    await db.update(schema.planes).set({ fuel: 6300 }).where(eq(schema.planes.id, 'plane-starter'));
+    await db.update(schema.planes).set({ locationIcao: 'EDDF' }).where(eq(schema.planes.id, 'plane-starter'));
   });
 
   it('flies the plane and returns the full snapshot with departure + destination set', async () => {

app/api/planes/[planeId]/refuel/route.test.ts

@@ -1,171 +0,0 @@
-import fs from 'node:fs/promises';
-import os from 'node:os';
-import path from 'node:path';
-import { eq } from 'drizzle-orm';
-import { afterAll, beforeAll, describe, expect, it } from 'vitest';
-import * as schema from '@/lib/db/schema';
-import { getGameDb } from '@/lib/db/client';
-import { loadAirportsGeoJson } from '@/lib/airports';
-import { haversineKm, initialBearingDeg } from '@/lib/geo';
-import { weatherFor } from '@/lib/weather';
-import { requiredFuelFor, windBurnFactor } from '@/lib/sim/movement';
-import { FUEL_PRICE_PER_L, PLANE_TYPES } from '@/lib/game/catalog';
-import { HUB_ICAO } from '@/lib/game/seed';
-import { POST } from './route';
-
-let dir: string;
-
-beforeAll(async () => {
-  // Same pattern as app/api/state/route.test.ts: point the DB singleton at a
-  // throwaway file (fresh module registry per test file → fresh singleton).
-  dir = await fs.mkdtemp(path.join(os.tmpdir(), 'flight-refuel-api-'));
-  process.env.FLIGHT_DB_PATH = path.join(dir, 'refuel.db');
-});
-
-afterAll(async () => {
-  delete process.env.FLIGHT_DB_PATH;
-  await fs.rm(dir, { recursive: true, force: true });
-});
-
-const post = (planeId: string, body?: unknown) =>
-  POST(
-    new Request(`http://localhost/api/planes/${planeId}/refuel`, {
-      method: 'POST',
-      headers: { 'Content-Type': 'application/json' },
-      body: body === undefined ? undefined : JSON.stringify(body),
-    }),
-    { params: Promise.resolve({ planeId }) },
-  );
-
-describe('POST /api/planes/:planeId/refuel', () => {
-  it('rejects an unknown id with 404', async () => {
-    const res = await post('ghost');
-    expect(res.status).toBe(404);
-  });
-
-  it('fills a partially empty tank and deducts (maxFuel − fuel) × FUEL_PRICE_PER_L from cash', async () => {
-    const { db } = await getGameDb();
-    await db.update(schema.planes).set({ fuel: 1_000 }).where(eq(schema.planes.id, 'plane-starter'));
-    const cashBefore = (await db.select().from(schema.account))[0].cash;
-
-    const res = await post('plane-starter');
-    expect(res.status).toBe(200);
-
-    const body = (await res.json()) as {
-      account: { cash: number };
-      planes: Array<{ id: string; fuel: number; maxFuel: number }>;
-    };
-    const cost = Math.round((PLANE_TYPES.atr72.maxFuel - 1_000) * FUEL_PRICE_PER_L * 100) / 100;
-    expect(body.account.cash).toBeCloseTo(cashBefore - cost, 6);
-
-    const plane = body.planes.find((p) => p.id === 'plane-starter')!;
-    expect(plane.fuel).toBe(PLANE_TYPES.atr72.maxFuel); // back to full
-  });
-
-  it('rejects a flying plane with 409', async () => {
-    const { db } = await getGameDb();
-    await db.update(schema.planes)
-      .set({ status: 'flying', departureSimTime: Date.now(), destIcao: 'LEMD' })
-      .where(eq(schema.planes.id, 'plane-starter'));
-
-    const res = await post('plane-starter');
-    expect(res.status).toBe(409);
-    expect(((await res.json()) as { error: string }).error).toMatch(/flying/);
-
-    // Ground it again for later tests.
-    await db.update(schema.planes)
-      .set({ status: 'available', departureSimTime: null, destIcao: null })
-      .where(eq(schema.planes.id, 'plane-starter'));
-  });
-
-  it('rejects the fill-up with 409 when cash is below the cost', async () => {
-    const { db } = await getGameDb();
-    await db.update(schema.planes).set({ fuel: 1_000 }).where(eq(schema.planes.id, 'plane-starter'));
-    await db.update(schema.account).set({ cash: 10 }); // cost is ~4960
-
-    const res = await post('plane-starter');
-    expect(res.status).toBe(409);
-    expect(((await res.json()) as { error: string }).error).toMatch(/insufficient funds/i);
-  });
-
-  it('accepts an explicit {mode:"full"} body exactly like no body', async () => {
-    const { db } = await getGameDb();
-    await db.update(schema.account).set({ cash: 50_000 }); // previous test left the account poor
-    await db.update(schema.planes).set({ fuel: 1_000 }).where(eq(schema.planes.id, 'plane-starter'));
-
-    const res = await post('plane-starter', { mode: 'full' });
-    expect(res.status).toBe(200);
-    const body = (await res.json()) as { planes: Array<{ id: string; fuel: number }> };
-    expect(body.planes.find((p) => p.id === 'plane-starter')!.fuel).toBe(PLANE_TYPES.atr72.maxFuel);
-  });
-
-  it('rejects an unknown mode with 400', async () => {
-    const res = await post('plane-starter', { mode: 'half' });
-    expect(res.status).toBe(400);
-    expect(((await res.json()) as { error: string }).error).toMatch(/mode/);
-  });
-
-  it('rejects forFlight without a packageId with 400', async () => {
-    const res = await post('plane-starter', { mode: 'forFlight' });
-    expect(res.status).toBe(400);
-    expect(((await res.json()) as { error: string }).error).toMatch(/packageId/);
-  });
-
-  it('rejects an unknown body field with 400', async () => {
-    const res = await post('plane-starter', { liters: 100 });
-    expect(res.status).toBe(400);
-    expect(((await res.json()) as { error: string }).error).toMatch(/unknown field/);
-  });
-
-  it('rejects invalid JSON with 400', async () => {
-    const res = await POST(
-      new Request(`http://localhost/api/planes/plane-starter/refuel`, { method: 'POST', body: '{nope' }),
-      { params: Promise.resolve({ planeId: 'plane-starter' }) },
-    );
-    expect(res.status).toBe(400);
-  });
-
-  it('forFlight buys 150% of the weather-adjusted leg requirement', async () => {
-    const { db } = await getGameDb();
-    await db.update(schema.account).set({ cash: 50_000 });
-    // A loaded EDDF → LEMD package on the starter (direct row — loadPackage is covered in actions tests).
-    await db.insert(schema.packages).values({
-      id: 'p-ff-api', originIcao: HUB_ICAO, destIcao: 'LEMD', reward: 1_000, cargoType: 'Mail', cargoCount: 4,
-      deadlineSimTime: Date.now() + 24 * 3_600_000, status: 'loaded', planeId: 'plane-starter', createdSimTime: Date.now(),
-    });
-
-    const fc = await loadAirportsGeoJson();
-    const from = fc.features.find((f) => f.properties.icao === HUB_ICAO)!.properties;
-    const to = fc.features.find((f) => f.properties.icao === 'LEMD')!.properties;
-    const km = haversineKm(from.lat, from.lon, to.lat, to.lon);
-    const type = PLANE_TYPES.atr72;
-    // Same wind-adjusted requirement the server computes (v0.36.0).
-    const w = weatherFor(HUB_ICAO);
-    const required = requiredFuelFor(
-      type.burnPerKm * windBurnFactor(w.windKt, w.windDirDeg, initialBearingDeg(from.lat, from.lon, to.lat, to.lon)),
-      type.emptyWeightKg,
-      type.maxFuel,
-      km,
-    );
-
-    const startFuel = Math.round(required / 2); // partial tank so L > 0
-    await db.update(schema.planes).set({ fuel: startFuel }).where(eq(schema.planes.id, 'plane-starter'));
-    const cashBefore = (await db.select().from(schema.account))[0].cash;
-
-    const res = await post('plane-starter', { mode: 'forFlight', packageId: 'p-ff-api' });
-    expect(res.status).toBe(200);
-
-    const body = (await res.json()) as {
-      account: { cash: number };
-      planes: Array<{ id: string; fuel: number }>;
-    };
-    // ISS-071: target is 150% of the requirement, capped at tank capacity.
-    const targetFuel = Math.min(type.maxFuel, Math.max(startFuel, required * 1.5));
-    const cost = Math.round((targetFuel - startFuel) * FUEL_PRICE_PER_L * 100) / 100;
-    expect(body.account.cash).toBeCloseTo(cashBefore - cost, 6);
-    expect(body.planes.find((p) => p.id === 'plane-starter')!.fuel).toBeCloseTo(targetFuel, 6);
-
-    // Clean up the test package.
-    await db.delete(schema.packages).where(eq(schema.packages.id, 'p-ff-api'));
-  });
-});

app/api/planes/[planeId]/refuel/route.ts

@@ -1,47 +0,0 @@
-import { performAction, refuelPlane } from '@/lib/game/actions';
-
-// POST /api/planes/:planeId/refuel (v0.8.0; optional body v0.16.0) — fills a grounded
-// plane at the fuel price per added liter and deducts the cost from cash. The body is
-// OPTIONAL: no body, {} or {mode:'full'} fill to maxFuel (the original behavior);
-// {mode:'forFlight', packageId} adds just enough for that loaded package's destination
-// leg. 400 bad body (unknown field, unknown mode, forFlight without packageId); 404
-// unknown plane/package id; 409 if the plane is flying, the package isn't loaded on it
-// (or is expired), the leg doesn't fit a full tank, or cash is insufficient. On success
-// returns the full state snapshot (fuel raised by exactly the added liters).
-
-export async function POST(req: Request, ctx: { params: Promise<{ planeId: string }> }) {
-  const { planeId } = await ctx.params;
-
-  let body: unknown;
-  try {
-    const text = await req.text();
-    body = text ? JSON.parse(text) : {};
-  } catch {
-    return Response.json({ error: 'invalid JSON body' }, { status: 400 });
-  }
-  if (typeof body !== 'object' || body === null || Array.isArray(body)) {
-    return Response.json({ error: 'body must be a JSON object' }, { status: 400 });
-  }
-  const input = body as Record<string, unknown>;
-  for (const key of Object.keys(input)) {
-    if (key !== 'mode' && key !== 'packageId') {
-      return Response.json({ error: `unknown field "${key}"` }, { status: 400 });
-    }
-  }
-  const mode = input.mode ?? 'full';
-  if (mode !== 'full' && mode !== 'forFlight') {
-    return Response.json({ error: 'mode must be "full" or "forFlight"' }, { status: 400 });
-  }
-  let packageId: string | undefined;
-  if (input.packageId !== undefined) {
-    if (typeof input.packageId !== 'string' || input.packageId.length === 0) {
-      return Response.json({ error: 'packageId must be a non-empty string' }, { status: 400 });
-    }
-    packageId = input.packageId;
-  }
-  if (mode === 'forFlight' && !packageId) {
-    return Response.json({ error: 'packageId is required when mode is "forFlight"' }, { status: 400 });
-  }
-
-  return performAction((inst) => refuelPlane(inst, planeId, { mode, packageId }));
-}

app/api/planes/[planeId]/repair/route.ts

@@ -0,0 +1,12 @@
+import { performAction, repairPlane } from '@/lib/game/actions';
+
+// POST /api/planes/:planeId/repair (v0.39.0, ISS-069) — no body. Restores a worn-out plane to
+// full health for the flat REPAIR_COST: it is grounded in "repairing" status until 3 sim days
+// pass, when the engine's tick flips it back to "available". A full-health repair is a free
+// no-op (cost 0). 404 unknown id; 409 plane not grounded or insufficient funds. On success
+// returns the full state snapshot.
+
+export async function POST(_req: Request, ctx: { params: Promise<{ planeId: string }> }) {
+  const { planeId } = await ctx.params;
+  return performAction((inst) => repairPlane(inst, planeId));
+}

app/api/test/set-fuel/route.ts

@@ -0,0 +1,65 @@
+import { eq } from 'drizzle-orm';
+import { getGameDb, persist } from '@/lib/db/client';
+import * as schema from '@/lib/db/schema';
+import { getStateSnapshot } from '@/lib/game/state';
+import { tickNow } from '@/lib/sim/engine';
+
+// TEST-ONLY hook (v0.42.0, ISS-082) — lets the e2e suite force a plane's fuel level now that the
+// manual /refuel endpoint is gone (dispatch auto-refuels instead). Disabled unless FLIGHT_TEST_HOOKS=1
+// (set in docker-compose.yml for the e2e instance only); every other deployment 404s here. Sibling of
+// /api/test/set-health — same gate, same conventions.
+//
+// POST /api/test/set-fuel
+//   body { planeId: string, fuel: number } — both required; planeId must name an existing plane
+//   (404 otherwise) and fuel a finite number in [0, the plane's maxFuel] (400 outside). Sets the
+//   planes row's fuel directly and returns the full state snapshot after ticking.
+
+export async function POST(req: Request) {
+  if (process.env.FLIGHT_TEST_HOOKS !== '1') {
+    return Response.json({ error: 'test hooks disabled' }, { status: 404 });
+  }
+
+  let body: unknown = {};
+  try {
+    const text = await req.text();
+    body = text ? JSON.parse(text) : {};
+  } catch {
+    return Response.json({ error: 'invalid JSON body' }, { status: 400 });
+  }
+  if (typeof body !== 'object' || body === null || Array.isArray(body)) {
+    return Response.json({ error: 'body must be a JSON object' }, { status: 400 });
+  }
+  const input = body as Record<string, unknown>;
+  for (const key of Object.keys(input)) {
+    if (key !== 'planeId' && key !== 'fuel') {
+      return Response.json({ error: `unknown field "${key}"` }, { status: 400 });
+    }
+  }
+  const planeId = input.planeId;
+  if (typeof planeId !== 'string' || planeId.length === 0) {
+    return Response.json({ error: 'planeId is required and must be a non-empty string' }, { status: 400 });
+  }
+  const fuel = input.fuel;
+  if (typeof fuel !== 'number' || !Number.isFinite(fuel)) {
+    return Response.json({ error: 'fuel is required and must be a finite number' }, { status: 400 });
+  }
+
+  try {
+    const inst = await getGameDb();
+    await tickNow(); // clock is current before the snapshot we return (same as siblings)
+    const rows = await inst.db.select().from(schema.planes).where(eq(schema.planes.id, planeId));
+    if (!rows[0]) {
+      return Response.json({ error: `plane ${planeId} not found` }, { status: 404 });
+    }
+    if (fuel < 0 || fuel > rows[0].maxFuel) {
+      return Response.json({ error: `fuel must be in [0, maxFuel] — this plane's tank holds ${rows[0].maxFuel} L` }, { status: 400 });
+    }
+
+    await inst.db.update(schema.planes).set({ fuel }).where(eq(schema.planes.id, planeId));
+    await persist(inst);
+    return Response.json(await getStateSnapshot());
+  } catch (err) {
+    console.error('test hook failed', err);
+    return Response.json({ error: 'test hook failed' }, { status: 500 });
+  }
+}

app/api/test/set-health/route.ts

@@ -0,0 +1,82 @@
+import { eq } from 'drizzle-orm';
+import { getGameDb, persist } from '@/lib/db/client';
+import * as schema from '@/lib/db/schema';
+import { getStateSnapshot } from '@/lib/game/state';
+import { tickNow } from '@/lib/sim/engine';
+
+// TEST-ONLY hook (v0.39.0, ISS-069) — lets the e2e suite force a plane's health and/or shorten an
+// active repair gate without flying thousands of km or waiting 3 sim days. Disabled unless
+// FLIGHT_TEST_HOOKS=1 (set in docker-compose.yml for the e2e instance only); every other
+// deployment 404s here. Sibling of /api/test/add-cash — same gate, same conventions.
+//
+// POST /api/test/set-health
+//   body { planeId: string, health?: number, repairUntilMs?: number }
+//   - planeId is required and must name an existing plane (404 otherwise);
+//   - at least one of health / repairUntilMs must be present;
+//   - health must be a finite number in [0, 100];
+//   - repairUntilMs sets repair_until_sim_time = clock + repairUntilMs (the expire-package
+//     near-term-gate precedent) so the next advancing tick flips a shortened repair back.
+//   Returns the full state snapshot after ticking.
+
+export async function POST(req: Request) {
+  if (process.env.FLIGHT_TEST_HOOKS !== '1') {
+    return Response.json({ error: 'test hooks disabled' }, { status: 404 });
+  }
+
+  let body: unknown = {};
+  try {
+    const text = await req.text();
+    body = text ? JSON.parse(text) : {};
+  } catch {
+    return Response.json({ error: 'invalid JSON body' }, { status: 400 });
+  }
+  if (typeof body !== 'object' || body === null || Array.isArray(body)) {
+    return Response.json({ error: 'body must be a JSON object' }, { status: 400 });
+  }
+  const input = body as Record<string, unknown>;
+  for (const key of Object.keys(input)) {
+    if (key !== 'planeId' && key !== 'health' && key !== 'repairUntilMs') {
+      return Response.json({ error: `unknown field "${key}"` }, { status: 400 });
+    }
+  }
+  const planeId = input.planeId;
+  if (typeof planeId !== 'string' || planeId.length === 0) {
+    return Response.json({ error: 'planeId is required and must be a non-empty string' }, { status: 400 });
+  }
+  let health: number | undefined;
+  if (input.health !== undefined) {
+    if (typeof input.health !== 'number' || !Number.isFinite(input.health) || input.health < 0 || input.health > 100) {
+      return Response.json({ error: 'health must be a finite number in [0, 100]' }, { status: 400 });
+    }
+    health = input.health;
+  }
+  let repairUntilMs: number | undefined;
+  if (input.repairUntilMs !== undefined) {
+    if (typeof input.repairUntilMs !== 'number' || !Number.isFinite(input.repairUntilMs)) {
+      return Response.json({ error: 'repairUntilMs must be a finite number' }, { status: 400 });
+    }
+    repairUntilMs = input.repairUntilMs;
+  }
+  if (health === undefined && repairUntilMs === undefined) {
+    return Response.json({ error: 'at least one of health or repairUntilMs is required' }, { status: 400 });
+  }
+
+  try {
+    const inst = await getGameDb();
+    const sim = await tickNow(); // clock is current before we set the gate (same as siblings)
+    const rows = await inst.db.select().from(schema.planes).where(eq(schema.planes.id, planeId));
+    if (!rows[0]) {
+      return Response.json({ error: `plane ${planeId} not found` }, { status: 404 });
+    }
+
+    const sets: Partial<Pick<schema.PlaneRow, 'health' | 'repairUntilSimTime'>> = {};
+    if (health !== undefined) sets.health = health;
+    if (repairUntilMs !== undefined) sets.repairUntilSimTime = Math.round(sim.clockMs + repairUntilMs);
+    await inst.db.update(schema.planes).set(sets).where(eq(schema.planes.id, planeId));
+    await persist(inst);
+    return Response.json(await getStateSnapshot());
+  } catch (err) {
+    console.error('test hook failed', err);
+    return Response.json({ error: 'test hook failed' }, { status: 500 });
+  }
+}

app/globals.css

@@ -48,6 +48,16 @@ body {
   color: #94a3b8;
 }
 
+/* ISS-080 (v0.40.0): the version tag links to the repo's CHANGELOG.md — keep it subtle, like the rest of the header. */
+.app-header a {
+  color: #7dd3fc;
+  text-decoration: none;
+}
+
+.app-header a:hover {
+  text-decoration: underline;
+}
+
 /* Style switcher — kept subtle, like the version tag. */
 .style-switch {
   font-size: 12px;
@@ -214,6 +224,17 @@ body {
   color: #bfdbfe;
 }
 
+/* v0.39.0 (ISS-069): maintenance pills on fleet rows — broken = red, in repair = amber. */
+.status-broken {
+  background: rgba(239, 68, 68, 0.25);
+  color: #fecaca;
+}
+
+.status-repairing {
+  background: rgba(245, 158, 11, 0.25);
+  color: #fde68a;
+}
+
 /* v0.37.0 (ISS-073): special-status pill on package rows — sky-blue accent, modeled on .plane-status. */
 .special-badge {
   font-size: 11px;
@@ -237,6 +258,26 @@ body {
   background: #34d399;
 }
 
+/* v0.39.0 (ISS-069): health bar — modeled on .fuel-bar, amber fill. */
+.health-bar {
+  height: 4px;
+  border-radius: 2px;
+  background: rgba(148, 163, 184, 0.25);
+  margin: 2px 0 4px;
+  overflow: hidden;
+}
+
+.health-bar > div {
+  height: 100%;
+  border-radius: 2px;
+  background: #f59e0b;
+}
+
+/* v0.39.0 (ISS-069): the per-plane Repair button sits under the readout row. */
+.repair-btn {
+  margin-top: 6px;
+}
+
 .plane-sub {
   display: flex;
   justify-content: space-between;

app/page.tsx

@@ -44,7 +44,7 @@ export default function Home() {
   return (
     <div className="app-shell">
       {/* ISS-021 (v0.20.0) — applySnapshot also reaches the left pane: its On board section's
-          refuel/fly/abandon actions push their response snapshot into the shared state */}
+          fly/abandon actions push their response snapshot into the shared state */}
       <LeftPane state={state} loading={loading} error={error} onRefresh={refresh} applySnapshot={applySnapshot} onHover={setHovered} onError={onError} />
       {/* v0.11.0 — the same polled snapshot drives the map's plane markers + route lines;
           ISS-010 (v0.18.0) — applySnapshot lets the airport popup's Relocate row push its

components/LeftPane.tsx

@@ -3,7 +3,7 @@
 import { useCallback, useEffect, useRef, useState, type ChangeEvent } from 'react';
 import type { GeoJsonFeatureCollection } from '@/lib/airports';
 import type { PlaneState, StateSnapshot } from '@/lib/game/state';
-import { FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT, PLANE_TYPES, repRate } from '@/lib/game/catalog';
+import { PLANE_TYPES } from '@/lib/game/catalog';
 import { abandonPenalty } from '@/lib/game/penalty';
 import { formatCash, formatDeadlineRelative, formatFuel, formatSimClock, formatSpecialLabel } from '@/lib/format';
 import { TIME_SCALES, scaleToSlider, sliderToScale } from '@/lib/timeScale';
@@ -19,7 +19,7 @@ interface LeftPaneProps {
   // The shell's single-poll refresh — called after a sim-control POST so the pane updates immediately.
   onRefresh: () => void;
   // ISS-021 (v0.20.0): push the full snapshot returned by an action endpoint into the shared shell
-  // state — needed now that the per-plane cargo rows' refuel/fly/abandon actions live in this pane.
+  // state — needed now that the per-plane cargo rows' fly/abandon actions live in this pane.
   applySnapshot: (snapshot: StateSnapshot) => void;
   // ISS-002 (v0.15.0): report fleet-row hovers to the shell so the map can highlight the plane.
   onHover: (target: HoverTarget | null) => void;
@@ -101,11 +101,6 @@ export default function LeftPane({ state, loading, error, onRefresh, applySnapsh
   const [relocatePlaneId, setRelocatePlaneId] = useState<string | null>(null);
   const [relocateDestIcao, setRelocateDestIcao] = useState<string | null>(null);
 
-  // ISS-035 (v0.23.0): Refuel-to-full selection — moved here from the right-pane market row; same
-  // "effective selection" pattern as Relocate above: the user's pick while it stays refuelable, else
-  // a sensible default (first grounded plane with fuel below max).
-  const [refuelPlaneId, setRefuelPlaneId] = useState<string | null>(null);
-
   // ISS-010 (v0.18.0): one-time /api/airports fetch per page life — destination options for the
   // Relocate section, sorted by name so e2e selection is stable. Same promise-ref pattern as Map.tsx;
   // on failure airportOptions stays null and the Relocate button simply remains disabled. Moved here
@@ -202,27 +197,16 @@ export default function LeftPane({ state, loading, error, onRefresh, applySnapsh
   // endpoint (pure repositioning, no package needed since v0.12.0). Moved here from the right-pane
   // market row; with state null both fall back to null and the section isn't rendered.
   // ISS-053 (v0.32.0): widened from grounded-only to ALL planes — a flying plane's relocation is
-  // queued instead of started immediately (see relocate-go below). `grounded` stays for Refuel.
+  // queued instead of started immediately (see relocate-go below).
   const relocatable = state ? state.planes : [];
   const relocatePlane = relocatable.find((p) => p.id === relocatePlaneId) ?? relocatable[0] ?? null;
   const relocateDest =
     airportOptions === null ? null : airportOptions.find((a) => a.icao === relocateDestIcao) ?? airportOptions[0] ?? null;
-
+  // ISS-077 (v0.41.0): while flying, the Relocate click would POST /queue — block it when the selected
-  // ISS-035 (v0.23.0): Refuel-to-full — any GROUNDED plane with fuel below max can be topped up via the
+  // destination is already active or queued (the server rejects that with 409). Grounded planes are unaffected.
-  // existing refuel endpoint (no body → server defaults to mode 'full'). Moved here from the right-pane
+  const relocateBlocked =
-  // market row; grounded-only, and with state null falls back to null.
+    relocatePlane?.status === 'flying' && relocateDest !== null &&
-  const grounded = relocatable.filter((p) => p.status === 'available');
+    (relocatePlane.destIcao === relocateDest.icao || relocatePlane.queue.includes(relocateDest.icao));
-  const refuelable = grounded.filter((p) => p.fuel < p.maxFuel);
-  const refuelPlane =
-    (state?.planes.find((p) => p.id === refuelPlaneId && p.status === 'available' && p.fuel < p.maxFuel)) ??
-    refuelable[0] ??
-    null;
-  // v0.38.0 (ISS-072): rep-scaled preview — same formula as the server's refuelPlane 'full' mode.
-  const fuelDiscountRate = state ? repRate(state.account.reputation, FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT) : 0;
-  const refuelCost =
-    refuelPlane && state
-      ? Math.round((refuelPlane.maxFuel - refuelPlane.fuel) * state.fuelPricePerL * (1 - fuelDiscountRate) * 100) / 100
-      : null;
 
   // Slider commit (v0.9.1): the displayed value follows the drag optimistically via
   // pendingScale; POST /api/sim fires after a 250 ms debounce, or immediately when the
@@ -368,19 +352,50 @@ export default function LeftPane({ state, loading, error, onRefresh, applySnapsh
                             )}
                           </>
                         ) : (
-                          <span className="plane-status status-available">{p.locationIcao}</span>
+                          <>
+                            <span className="plane-status status-available">{p.locationIcao}</span>
+                            {/* v0.39.0 (ISS-069): maintenance pills — "in repair" while the gate runs, "broken" at zero health. */}
+                            {p.status === 'repairing' && (
+                              <span data-testid={`plane-repairing-${p.id}`} className="plane-status status-repairing">in repair</span>
+                            )}
+                            {p.health <= 0 && (
+                              <span data-testid={`plane-broken-${p.id}`} className="plane-status status-broken">broken</span>
+                            )}
+                          </>
                         )}
                       </div>
                       <div className="fuel-bar" aria-hidden="true">
                         <div style={{ width: `${Math.max(0, Math.min(100, (p.fuel / p.maxFuel) * 100))}%` }} />
                       </div>
+                      {/* v0.39.0 (ISS-069): health bar — sibling of the fuel bar, amber fill. */}
+                      <div className="health-bar" aria-hidden="true">
+                        <div style={{ width: `${Math.max(0, Math.min(100, p.health))}%` }} />
+                      </div>
                       <div className="plane-sub">
                         <span data-testid={`plane-fuel-${p.id}`}>{formatFuel(p.fuel, p.maxFuel)}</span>
+                        {/* v0.39.0 (ISS-069): health percentage next to the fuel readout. */}
+                        <span data-testid={`plane-health-${p.id}`}>{Math.round(p.health)}%</span>
                         <span data-testid={`plane-loadout-${p.id}`}>{loadoutFor(state, p)}</span>
                         <span className="plane-loc">{planeLocation(p)}</span>
                       </div>
+                      {/* v0.39.0 (ISS-069): repair — grounded plane with worn health; flat cost is server-side only (no preview). */}
+                      {p.status === 'available' && p.health < 100 && (
+                        <button
+                          type="button"
+                          data-testid={`repair-${p.id}`}
+                          className="pane-btn repair-btn"
+                          disabled={actionsBusy}
+                          onClick={() => void runAction(`/api/planes/${p.id}/repair`)}
+                        >
+                          Repair
+                        </button>
+                      )}
                       {cargo.map((pkg) => {
                         const penalty = abandonPenalty(pkg, clockMs);
+                        // ISS-077 (v0.41.0): while flying the click would POST /queue — disable it when the
+                        // destination is already active or queued (the server rejects that with 409). Grounded
+                        // clicks go to /fly, which has no such conflict.
+                        const alreadyQueued = p.status === 'flying' && (p.destIcao === pkg.destIcao || p.queue.includes(pkg.destIcao));
                         return (
                           // ISS-025 (v0.22.0): hovering a loaded package draws its full origin→dest trace on the map —
                           // same as job-list rows — and keeps this plane's halo lit via planeId. Leaving the row restores
@@ -397,25 +412,19 @@ export default function LeftPane({ state, loading, error, onRefresh, applySnapsh
                               type="button"
                               data-testid={`fly-to-${pkg.id}`}
                               className="pane-btn onboard-fly-btn"
-                              disabled={actionsBusy}
+                              disabled={actionsBusy || alreadyQueued}
+                              title={alreadyQueued ? 'Already in flight queue' : undefined}
                               // ISS-053 (v0.32.0): a flying plane can't start another leg — the click queues it instead,
                               // so "Fly to …" works from any state and the queue needs no dedicated input.
                               onClick={() => void runAction(`/api/planes/${p.id}/${p.status === 'flying' ? 'queue' : 'fly'}`, { destIcao: pkg.destIcao })}
                             >
-                              <span className="onboard-fly-label" title={`Fly to ${pkg.destName}`}>
+                              {/* ISS-081 (v0.40.0): ICAO tags instead of full airport names. */}
-                                Fly to {pkg.destName}
+                              <span className="onboard-fly-label" title={`Fly to ${pkg.destIcao}`}>
+                                Fly to {pkg.destIcao}
                               </span>
                             </button>
+                            {/* ISS-082 (v0.42.0): the per-leg Refuel button is gone — dispatch auto-refuels. */}
                             <div className="onboard-actions">
-                              <button
-                                type="button"
-                                data-testid={`refuel-for-${pkg.id}`}
-                                className="pane-btn"
-                                disabled={actionsBusy || p.status !== 'available'}
-                                onClick={() => void runAction(`/api/planes/${p.id}/refuel`, { mode: 'forFlight', packageId: pkg.id })}
-                              >
-                                Refuel
-                              </button>
                               <button
                                 type="button"
                                 data-testid={`abandon-${pkg.id}`}
@@ -428,7 +437,10 @@ export default function LeftPane({ state, loading, error, onRefresh, applySnapsh
                               </button>
                             </div>
                             <div className="contract-sub">
-                              <span className="contract-route">{pkg.originName} → {pkg.destName}</span>
+                              {/* ISS-081 (v0.40.0): ICAO tags instead of full airport names. */}
+                              <span data-testid={`onboard-route-${pkg.id}`} className="contract-route">
+                                {pkg.originIcao} → {pkg.destIcao}
+                              </span>
                               {/* v0.37.0 (ISS-073): special-status badge — rendered only when the package has one. */}
                               {pkg.special && (
                                 <span data-testid={`package-special-${pkg.id}`} className="special-badge">
@@ -520,7 +532,9 @@ export default function LeftPane({ state, loading, error, onRefresh, applySnapsh
                 onChange={(e) => setRelocateDestIcao(e.target.value || null)}
               >
                 {airportOptions?.map((a) => (
-                  <option key={a.icao} value={a.icao}>
+                  // ISS-077 (v0.41.0): a flying plane's active/queued airports can't be re-selected — the
+                  // server would reject them with 409; native disabled options, no text change.
+                  <option key={a.icao} value={a.icao} disabled={relocatePlane?.status === 'flying' && (relocatePlane.destIcao === a.icao || relocatePlane.queue.includes(a.icao))}>
                     {a.name}
                   </option>
                 ))}
@@ -529,7 +543,7 @@ export default function LeftPane({ state, loading, error, onRefresh, applySnapsh
                 type="button"
                 data-testid="relocate-go"
                 className="pane-btn"
-                disabled={actionsBusy || relocatePlane === null || relocateDest === null}
+                disabled={actionsBusy || relocatePlane === null || relocateDest === null || relocateBlocked}
                 // ISS-053 (v0.32.0): a flying plane can't start another leg — queue it instead, so the
                 // relocation takes off when the current one lands.
                 onClick={() => {
@@ -543,53 +557,7 @@ export default function LeftPane({ state, loading, error, onRefresh, applySnapsh
             </div>
           </section>
 
-          {/* ISS-035 (v0.23.0): moved here from the right-pane market row — it belongs with everything else
+          {/* ISS-082 (v0.42.0): the "Refuel to full" section is gone — dispatch auto-refuels instead. */}
-              about our planes, next to Relocate. Plain section: no hover handlers (refuel is not a route). */}
-          <section className="pane-section" data-testid="refuel-section">
-            <h3 className="pane-heading">Refuel</h3>
-            {/* Moved verbatim from the right-pane Market section — same testids/labels; the per-package
-                "Refuel" button in the fleet rows (mode 'forFlight') is a different feature and stays there. */}
-            <div className="market-row">
-              {refuelable.length === 0 ? (
-                <span data-testid="market-refuel-none" className="pane-muted">
-                  All tanks full.
-                </span>
-              ) : (
-                <>
-                  <select
-                    data-testid="market-refuel-plane"
-                    aria-label="Plane to refuel"
-                    value={refuelPlane?.id ?? ''}
-                    onChange={(e) => setRefuelPlaneId(e.target.value || null)}
-                  >
-                    {refuelable.map((p) => (
-                      <option key={p.id} value={p.id}>
-                        {PLANE_TYPES[p.model]?.name ?? p.model} — {Math.round(p.fuel)} / {p.maxFuel} L
-                      </option>
-                    ))}
-                  </select>
-                  <span data-testid="market-refuel-cost" className="market-preview">
-                    {refuelCost !== null ? formatCash(refuelCost) : ''}
-                  </span>
-                  {/* v0.38.0 (ISS-072): rep discount hint — only when the account actually gets one. */}
-                  {fuelDiscountRate > 0 && (
-                    <span data-testid="refuel-discount" className="special-badge">−{Math.round(fuelDiscountRate * 100)}%</span>
-                  )}
-                </>
-              )}
-              <button
-                type="button"
-                data-testid="market-refuel"
-                className="pane-btn"
-                disabled={actionsBusy || refuelPlane === null}
-                onClick={() => {
-                  if (refuelPlane) void runAction(`/api/planes/${refuelPlane.id}/refuel`);
-                }}
-              >
-                Refuel to full
-              </button>
-            </div>
-          </section>
 
           <section className="pane-section">
             <h3 className="pane-heading">Time</h3>

components/Map.tsx

@@ -153,10 +153,20 @@ export default function FlightMap({ state, hovered, applySnapshot }: MapProps) {
       // ISS-040 (v0.23.2): an on-board package's trace starts from the carrier plane's LIVE position,
       // not its origin airport — identical to before while grounded at the pickup, different once it
       // has departed with cargo still loaded. No carrier in state yet → fall back to the ICAO trace.
+      // ISS-077 (v0.41.0): a FLYING carrier's trace starts at its LANDING airport (destIcao), not the
+      // live mid-flight position — the hover previews what happens AFTER this leg lands, and the solid
+      // active-leg + dotted queue layers already show where it is now. Grounded / no active leg keeps
+      // today's behavior exactly (live position = the plane's airport). destIcao missing from the
+      // index → fall back to the live position rather than guessing.
       const idx = airportsIndexRef.current ?? new Map();
       const carrier = h?.kind === 'package' && h.planeId ? stateRef.current?.planes.find((p) => p.id === h.planeId) : undefined;
+      const landing = carrier?.status === 'flying' && carrier.destIcao ? idx.get(carrier.destIcao) : undefined;
       void hoverSource.setData(
-        carrier ? hoverTraceGeoJson({ lat: carrier.lat, lon: carrier.lon }, toIcao, idx) : hoverRouteGeoJson(fromIcao, toIcao, idx),
+        landing
+          ? hoverTraceGeoJson(landing, toIcao, idx)
+          : carrier
+            ? hoverTraceGeoJson({ lat: carrier.lat, lon: carrier.lon }, toIcao, idx)
+            : hoverRouteGeoJson(fromIcao, toIcao, idx),
       );
     }
     // Package hovers ring BOTH endpoints (v0.15.0 behavior); 'route' hovers ring the TARGET only —
@@ -537,7 +547,9 @@ export default function FlightMap({ state, hovered, applySnapshot }: MapProps) {
     <div className="map-wrap">
       <header data-testid="app-header" className="app-header">
         <h1>Flight Ops</h1>
-        <small>v{pkg.version}</small>
+        <a data-testid="app-version" href="https://git.kkhost.pl/OpenCode/Flight-Ops/src/branch/master/CHANGELOG.md" target="_blank" rel="noreferrer">
+          <small>v{pkg.version}</small>
+        </a>
         <select
           data-testid="style-switch"
           className="style-switch"

components/right-pane.test.ts

@@ -24,6 +24,8 @@ function plane(over: Partial<PlaneState> & Pick<PlaneState, 'id'>): PlaneState {
     departureSimTime: null,
     lat: 50,
     lon: 8.5,
+    health: 100, // v0.39.0 (ISS-069) — full-health fixture default
+    repairUntilSimTime: null,
     queue: [],
     ...over,
   };

e2e/actions.spec.ts

@@ -5,8 +5,6 @@ import { expect, test } from '@playwright/test';
 import { initialBearingDeg } from '../lib/geo';
 import { weatherFor } from '../lib/weather';
 import { windBurnFactor } from '../lib/sim/movement';
-// v0.38.0 (ISS-072) — reputation discounts: expectations computed from the LIVE snapshot's rep with the real helpers.
-import { FUEL_DISCOUNT_PER_REP, FUEL_PRICE_PER_L, MAX_FUEL_DISCOUNT, repRate } from '../lib/game/catalog';
 
 // v0.12.0 package model against the live origin (https://flight.dev.kkhost.pl):
 // the full core loop through the UI — hook creates a short package at EDDF → Load
@@ -18,12 +16,9 @@ import { FUEL_DISCOUNT_PER_REP, FUEL_PRICE_PER_L, MAX_FUEL_DISCOUNT, repRate } f
 
 const SCALE = 1000; // fastest sim speed (v0.14.0 ladder top) — keeps flights to seconds of real time
 const HUB = 'EDDF'; // Frankfurt Main — the seeded starter plane's home base (lib/game/seed.ts)
-const FAR = 'LEZL'; // Seville — a long leg: under the v0.16.0 weighted model a full tank covers the
-                    // round trip, but the return leaves too little for another outbound
 
-// Mirrors lib/sim/movement.ts (v0.16.0 weight-proportional burn) + lib/game/catalog.ts (atr72).
+// Mirrors lib/sim/movement.ts (v0.16.0 weight-proportional burn).
 const FUEL_DENSITY_KG_PER_L = 0.8; // Jet-A1 density — must match FUEL_DENSITY_KG_PER_L in movement.ts
-// FUEL_PRICE_PER_L is imported from ../lib/game/catalog (v0.38.0) instead of mirrored here.
 const REP_BASE = 1; // lib/sim/engine.ts
 const REP_PER_KM = 0.0005;
 
@@ -79,6 +74,14 @@ async function postSim(page: Page, body: Record<string, unknown>): Promise<void>
   expect(res.ok()).toBeTruthy();
 }
 
+// Test hook (FLIGHT_TEST_HOOKS=1): top a plane's tank back to full — replaces the removed /refuel
+// endpoint (ISS-082). Reads maxFuel from the snapshot so no catalog mirror is needed.
+async function setFuelFull(page: Page, planeId: string): Promise<void> {
+  const s = await getState(page);
+  const p = s.planes.find((x) => x.id === planeId)!;
+  expect((await page.request.post('/api/test/set-fuel', { data: { planeId, fuel: p.maxFuel } })).status()).toBe(200);
+}
+
 // Set the time scale and VERIFY from the response that it stuck — if something external ever
 // resets the live instance's controls mid-test, fail loudly here instead of timing out later.
 // ISS-041 also clears pause: a landing pauses the sim, so any fast-forward after one must
@@ -118,7 +121,11 @@ test.describe.configure({ mode: 'serial' }); // shared live DB — order matters
 // (repositioning needs no package — v0.12.0 manual flight), and abandon any leftover cargo so
 // exact cash/rep assertions start from a clean baseline even after an interrupted previous run.
 async function flyHomeViaApi(page: Page): Promise<void> {
-  let s = await getState(page);
+  // v0.39.0 (ISS-069): wear accumulates across the shared CI DB — restore full health and clear any
+  // active repair gate from an interrupted run before the steps below act on the starter, so the
+  // exact-fuel pins never see a worn or broken plane (broken planes burn ×1.5 more).
+  expect((await page.request.post('/api/test/set-health', { data: { planeId: 'plane-starter', health: 100, repairUntilMs: 0 } })).status()).toBe(200);
+  let s = await getState(page); // ticks — a shortened gate flips the plane back to available here
   let plane = s.planes.find((p) => p.id === 'plane-starter')!;
   if (plane.status === 'flying' || plane.locationIcao !== HUB) {
     // Fast-forward any leftover leg / repositioning flight (~20 s real time worst case at 1000×).
@@ -156,7 +163,7 @@ async function flyHomeViaApi(page: Page): Promise<void> {
 
 
 test('full core loop via UI: load → fly to destination → exact reward + rep on arrival', async ({ page }) => {
-  test.setTimeout(300_000); // self-heal (worst case ~20 s at 1000×) + two short flights + refuel
+  test.setTimeout(300_000); // self-heal (worst case ~20 s at 1000×) + two short flights
   // Self-heal: the starter plane may be anywhere from a previous run/spec.
   await flyHomeViaApi(page);
   const before = await getState(page);
@@ -188,8 +195,10 @@ test('full core loop via UI: load → fly to destination → exact reward + rep
   // package shows as loaded on the starter in the on-board section.
   const onboardRow = page.getByTestId(`onboard-package-${pkg.id}`);
   await expect(onboardRow, 'loaded package appears in the on-board list').toBeVisible();
+  // ISS-081 (v0.40.0): the on-board route shows ICAO tags, not full airport names.
+  await expect(page.getByTestId(`onboard-route-${pkg.id}`)).toContainText(`${HUB} → ${nearest.icao}`);
 
-  // FLY via the UI: click the destination name button in the on-board list.
+  // FLY via the UI: click the fly-to button in the on-board list (ISS-081: ICAO label).
   const flyBtn = page.getByTestId(`fly-to-${pkg.id}`);
   await expect(flyBtn).toBeEnabled();
   await flyBtn.click();
@@ -241,15 +250,8 @@ test('full core loop via UI: load → fly to destination → exact reward + rep
     6,
   );
 
-  // Refuel via the API: cost = (maxFuel − fuel) × FUEL_PRICE_PER_L, rep-scaled (v0.38.0, ISS-072), deducted exactly.
+  // ISS-082 (v0.42.0): manual refuel is gone — the return leg below auto-refuels on dispatch; the
-  const refuelRes = await page.request.post(`/api/planes/${planeId}/refuel`);
+  // exact top-up cost delta is pinned in e2e/right-pane.spec.ts instead of here.
-  expect(refuelRes.ok()).toBeTruthy();
-  s = await getState(page);
-  const afterRefuel = s.planes.find((p) => p.id === planeId)!;
-  expect(afterRefuel.fuel).toBe(afterRefuel.maxFuel); // back to full
-  const fuelRate = repRate(s.account.reputation, FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT);
-  const refuelCost = Math.round((afterRefuel.maxFuel - landed.fuel) * FUEL_PRICE_PER_L * (1 - fuelRate) * 100) / 100;
-  expect(s.account.cash).toBeCloseTo(before.account.cash + pkg.reward - refuelCost, 6);
 
   // Restore: fly home (repositioning — no package needed in the v0.12.0 model). ISS-041: the
   // arrival above paused the sim, so re-set SCALE for the return leg (setScale clears pause).
@@ -341,9 +343,9 @@ test('expired packages deliver and abandon with no reward and no penalty', async
   expect(s.packages.find((p) => p.id === pkgB.id)!.status).toBe('abandoned');
   expect(s.account.cash).toBe(cashBeforeAbandon); // free — expired abandons cost nothing
 
-  // Restore: refuel + fly home. ISS-041: the LEMD arrival above paused the sim, so
+  // Restore: top up + fly home. ISS-041: the LEMD arrival above paused the sim, so
   // re-set SCALE for the return leg (setScale clears pause; the expiry wait's scale is kept).
-  await page.request.post('/api/planes/plane-starter/refuel');
+  await setFuelFull(page, 'plane-starter');
   await setScale(page, SCALE);
   const homeRes = await page.request.post('/api/planes/plane-starter/fly', { data: { destIcao: HUB } });
   expect(homeRes.ok()).toBeTruthy();
@@ -351,7 +353,7 @@ test('expired packages deliver and abandon with no reward and no penalty', async
 });
 
 test('load and fly validation paths (404 / 409 / 400)', async ({ page }) => {
-  test.setTimeout(600_000); // the FAR round trip alone is ~30 s real time at 1000×
+  test.setTimeout(300_000); // self-heal + one short hop each way at scale 1000
   await flyHomeViaApi(page);
 
   // Load a package whose origin the plane is not at → 409.
@@ -389,37 +391,10 @@ test('load and fly validation paths (404 / 409 / 400)', async ({ page }) => {
   expect(res.ok()).toBeTruthy();
   await expect.poll(async () => ((await getState(page)).planes.find((p) => p.id === 'plane-starter')!.locationIcao), { timeout: 120_000 }).toBe(HUB);
 
-  // Insufficient fuel (v0.16.0 weighted burn): a full tank covers the FAR round trip —
+  // ISS-082 (v0.42.0): the old "second outbound must 409 on insufficient fuel" pin is gone — dispatch
-  // the plane gets lighter as fuel burns off, so both legs fit — but landing back at the
+  // auto-refuels any full-tank-flyable leg, so a partial tank no longer blocks it. The remaining
-  // hub leaves too little for ANOTHER long leg: the second outbound must 409.
+  // insufficient-fuel case (a leg that doesn't fit even a FULL tank) is pinned in the unit tests and
-  const s0 = await getState(page);
+  // app/api/planes/[planeId]/fly/route.test.ts instead of spending ~60 s of CI time on a FAR round trip here.
-  const starter = s0.planes.find((p) => p.id === 'plane-starter')!;
-  expect(starter.locationIcao).toBe(HUB); // landed back at the hub from the hop above
-  if (starter.fuel < starter.maxFuel) {
-    await page.request.post('/api/planes/plane-starter/refuel'); // ensure a full tank for the long legs
-  }
-  const farRes = await page.request.post('/api/planes/plane-starter/fly', { data: { destIcao: FAR } });
-  expect(farRes.ok()).toBeTruthy();
-  await setScale(page, SCALE);
-  await expect.poll(async () => ((await getState(page)).planes.find((p) => p.id === 'plane-starter')!.status), { timeout: 240_000 }).toBe('available');
-
-  const sFar = await getState(page);
-  const atFar = sFar.planes.find((p) => p.id === 'plane-starter')!;
-  expect(atFar.locationIcao).toBe(FAR);
-  // The return leg fits: the weighted burn over it is less than what's left in the tank.
-  // ISS-041: the FAR arrival above paused the sim, so re-set SCALE for this leg (setScale clears pause).
-  await setScale(page, SCALE);
-  const backRes = await page.request.post('/api/planes/plane-starter/fly', { data: { destIcao: HUB } });
-  expect(backRes.ok()).toBeTruthy();
-  await expect.poll(async () => ((await getState(page)).planes.find((p) => p.id === 'plane-starter')!.locationIcao), { timeout: 240_000 }).toBe(HUB);
-
-  // …but the tank is now too light for another FAR leg.
-  const againFar = await page.request.post('/api/planes/plane-starter/fly', { data: { destIcao: FAR } });
-  expect(againFar.status()).toBe(409);
-  expect(((await againFar.json()) as { error: string }).error).toMatch(/insufficient fuel/i);
-
-  // Restore: refuel (the plane is already home).
-  await page.request.post('/api/planes/plane-starter/refuel');
 });
 
 // Great-circle distance in km — mirrors lib/geo.ts (same formula, same R).

e2e/api.spec.ts

@@ -31,7 +31,7 @@ test('GET /api/openapi serves the spec with all thirteen endpoints and the packa
     '/api/planes/{planeId}/fly',
     '/api/planes/{planeId}/queue',
     '/api/planes/{planeId}/queue/cancel',
-    '/api/planes/{planeId}/refuel',
+    '/api/planes/{planeId}/repair', // v0.39.0 (ISS-069)
     '/api/sim',
     '/api/state',
     '/api/version',

e2e/hover.spec.ts

@@ -15,6 +15,8 @@ const SCALE = 1000; // fastest sim speed (v0.14.0 ladder top) — keeps flights
 const HUB = 'EDDF'; // must match HUB_ICAO in lib/game/seed.ts
 // Madrid–Barajas — same long leg as e2e/map-interactions.spec.ts: ~1420 km → ~10 s at scale 1000.
 const DEST = 'LEMD';
+// Amsterdam — a third airport, distinct from hub and destination (the queued stop in the ISS-077 test).
+const QUEUE = 'EHAM';
 
 interface PlaneState {
   id: string;
@@ -79,6 +81,14 @@ async function createPackage(page: Page, fromIcao: string, toIcao: string): Prom
   return (await created.json()) as PackageState;
 }
 
+// Test hook (FLIGHT_TEST_HOOKS=1): top the starter's tank back to full — replaces the removed /refuel
+// endpoint (ISS-082). Reads maxFuel from the snapshot so no catalog mirror is needed.
+async function setFuelFull(page: Page, planeId: string): Promise<void> {
+  const s = await getState(page);
+  const p = s.planes.find((x) => x.id === planeId)!;
+  expect((await page.request.post('/api/test/set-fuel', { data: { planeId, fuel: p.maxFuel } })).status()).toBe(200);
+}
+
 // Self-heal: let any in-flight leg finish, then reposition plane-starter home via the API.
 async function flyHomeViaApi(page: Page): Promise<void> {
   const s0 = await getState(page);
@@ -443,9 +453,8 @@ test('hovering the fleet row of a flying plane highlights its route', async ({ p
   test.setTimeout(600_000); // self-heal + one flight at scale 1000 + fly-home cleanup
   await flyHomeViaApi(page);
 
-  // Full tank before departure — the EDDF↔LEMD round trip burns ~4970 L of the 6300 L tank.
+  // Full tank before departure — deterministic baseline (ISS-082 hook; dispatch would auto-refuel anyway).
-  const refuel = await page.request.post('/api/planes/plane-starter/refuel');
+  await setFuelFull(page, 'plane-starter');
-  expect(refuel.status()).toBe(200);
 
   await page.goto('/');
   await waitForAirportCount(page);
@@ -500,55 +509,52 @@ test('hovering the fleet row of a flying plane highlights its route', async ({ p
     .toBe(true);
 });
 
-test('hovering an on-board package while its carrier is mid-flight traces from current position', async ({ page }) => {
+test('hovering an on-board package while its carrier is mid-flight traces from the landing airport', async ({ page }) => {
   test.setTimeout(600_000); // self-heal + one flight at scale 1000 + fly-home cleanup
   await flyHomeViaApi(page);
 
-  // Full tank before departure — the EDDF↔LEMD round trip burns ~4970 L of the 6300 L tank.
+  // Full tank before departure — deterministic baseline (ISS-082 hook; dispatch would auto-refuel anyway).
-  const refuel = await page.request.post('/api/planes/plane-starter/refuel');
+  await setFuelFull(page, 'plane-starter');
-  expect(refuel.status()).toBe(200);
 
   await page.goto('/');
   await waitForAirportCount(page);
 
-  // Load + fly via the API (same pattern as e2e/map-interactions.spec.ts), then speed up.
+  // ISS-077 (v0.41.0): the package is destined for the QUEUED stop (EHAM), not the active leg's
-  const pkg = await createPackage(page, HUB, DEST);
+  // destination — load it, queue EHAM while grounded (pre-built routes are allowed), then start the
+  // HUB→DEST leg via the API (same pattern as e2e/map-interactions.spec.ts). The hover must trace
+  // from DEST (where this flight lands) to EHAM — NOT from the plane's live mid-flight position.
+  const pkg = await createPackage(page, HUB, QUEUE);
   const load = await page.request.post(`/api/packages/${pkg.id}/load`, { data: { planeId: 'plane-starter' } });
   expect(load.status()).toBe(200);
+  const queueRes = await page.request.post('/api/planes/plane-starter/queue', { data: { destIcao: QUEUE } });
+  expect(queueRes.status()).toBe(200);
   const fly = await page.request.post('/api/planes/plane-starter/fly', { data: { destIcao: DEST } });
   expect(fly.status()).toBe(200);
-  await setScale(page, SCALE);
+  // The endpoint's OWN post-action snapshot already shows the plane flying — no poll race.
+  const flyBody = (await fly.json()) as StateBody;
+  expect(flyBody.planes.find((p) => p.id === 'plane-starter')?.status).toBe('flying');
 
-  // Wait until the starter is GENUINELY mid-flight — its live position clearly away from EDDF in
+  // Freeze immediately: at a leftover scale of 1000 the ~10 s leg could otherwise land under us and
-  // both axes (well past HOVER_ROUTE_EPS_DEG) so "the trace starts at the plane" and "it starts at
+  // auto-chain the queued EHAM leg, which would change (or empty) the trace while we assert. Paused,
-  // the pickup airport" are distinguishable. The ~10 s leg at scale 1000 gives a wide window.
+  // every /api/state snapshot reports the same state — and the new rule's start point is the LANDING
-  const hubLonLat = await airportLonLat(page, HUB);
+  // airport regardless of progress, so no mid-flight position window is needed at all.
-  await expect
-    .poll(async () => {
-      const p = (await getState(page)).planes.find((x) => x.id === 'plane-starter');
-      if (!p || p.status !== 'flying') return false;
-      return Math.abs(p.lon - hubLonLat[0]) > 0.2 && Math.abs(p.lat - hubLonLat[1]) > 0.2;
-    }, { timeout: 60_000, message: 'waiting for plane-starter to be clearly away from the hub' })
-    .toBe(true);
-
-  // Freeze mid-flight so the position is stable while we assert (same pause pattern as the
-  // flying-plane hover test above): paused, every /api/state snapshot reports the same lat/lon.
   await postSim(page, { paused: true });
 
   const row = page.locator(`[data-testid="onboard-package-${pkg.id}"]`);
   await expect(row, 'the loaded package appears in the On board section').toBeVisible({ timeout: 15_000 });
 
-  // Both endpoints must be in-viewport for queryRenderedFeatures to see the trace.
+  // Both trace endpoints must be in-viewport for queryRenderedFeatures to see them.
-  await fitToAirports(page, [HUB, DEST]);
+  await fitToAirports(page, [DEST, QUEUE]);
 
-  const live = (await getState(page)).planes.find((x) => x.id === 'plane-starter')!;
-  const liveLonLat: [number, number] = [live.lon, live.lat]; // stable — the sim is paused
   const destLonLat = await airportLonLat(page, DEST);
+  const queueLonLat = await airportLonLat(page, QUEUE);
+  const hubLonLat = await airportLonLat(page, HUB);
 
   await row.hover();
-  // ISS-040 (v0.23.2): the trace starts at the carrier's LIVE position and ends at the destination,
+  // ISS-077 (v0.41.0): the trace starts at the LANDING airport (DEST) and ends at the package's
-  // and NO segment may start near the pickup airport (the old origin-based behavior). Same per-tile
+  // destination (the queued stop EHAM), and NO segment may start near the departure airport — that
-  // clipping/quantization caveats as expectHoverRoute — check endpoints across all segments with EPS.
+  // was the old live-position behavior right after takeoff. Same per-tile clipping/quantization
+  // caveats as expectHoverRoute — check endpoints across all segments with EPS.
   await expect.poll(async () => {
     const feats = (await renderedFeatures(page, ['hover-route'])) as Array<{ geometry?: { type: string; coordinates: [number, number][] } }>;
     const segs = feats.filter(
@@ -558,11 +564,14 @@ test('hovering an on-board package while its carrier is mid-flight traces from c
     if (!segs.length) return false;
     const near = (a: [number, number], b: [number, number]) =>
       Math.abs(a[0] - b[0]) <= HOVER_ROUTE_EPS_DEG && Math.abs(a[1] - b[1]) <= HOVER_ROUTE_EPS_DEG;
-    const startsAtLive = segs.some((f) => near(f.geometry.coordinates[0], liveLonLat));
+    const startsAtDest = segs.some((f) => near(f.geometry.coordinates[0], destLonLat));
-    const endsAtDest = segs.some((f) => near(f.geometry.coordinates[f.geometry.coordinates.length - 1], destLonLat));
+    const endsAtQueue = segs.some((f) => {
+      const c = f.geometry.coordinates;
+      return near(c[c.length - 1], queueLonLat);
+    });
     const noneStartsAtHub = !segs.some((f) => near(f.geometry.coordinates[0], hubLonLat));
-    return startsAtLive && endsAtDest && noneStartsAtHub;
+    return startsAtDest && endsAtQueue && noneStartsAtHub;
-  }, { timeout: 15_000, message: 'waiting for the hover-route trace to run from the live position to the destination' }).toBe(true);
+  }, { timeout: 15_000, message: 'waiting for the hover-route trace to run from the landing airport (DEST) to the queued stop' }).toBe(true);
 
   await unhover(page);
   await expect.poll(async () => (await renderedFeatures(page, ['hover-route'])).length, {
@@ -570,9 +579,12 @@ test('hovering an on-board package while its carrier is mid-flight traces from c
     message: 'waiting for the hover route trace to clear after mouseleave',
   }).toBe(0);
 
-  // Resume and fast-forward to arrival — landing at DEST auto-delivers the package (v0.12.0), so
+  // Cleanup: cancel the queued leg first so landing at DEST is a plain grounding (no auto-chain),
-  // flying home afterwards leaves the starter clean for the other specs.
+  // resume + fast-forward to arrival, abandon the still-loaded package (it was destined for EHAM,
-  await postSim(page, { timeScale: SCALE, paused: false });
+  // not DEST — it never delivered), then fly home.
+  const cancelRes = await page.request.post('/api/planes/plane-starter/queue/cancel', { data: { index: 0 } });
+  expect(cancelRes.status()).toBe(200);
+  await setScale(page, SCALE); // also clears the pause above
   await expect
     .poll(async () => {
       const p = (await getState(page)).planes.find((x) => x.id === 'plane-starter');
@@ -580,6 +592,9 @@ test('hovering an on-board package while its carrier is mid-flight traces from c
     }, { timeout: 120_000, message: `waiting for plane-starter to land at ${DEST}` })
     .toBe(true);
 
+  const abandon = await page.request.post(`/api/packages/${pkg.id}/abandon`);
+  expect(abandon.status()).toBe(200); // only possible once grounded — the poll above guarantees it
+
   // ISS-041: the arrival above paused the sim, so re-set SCALE for this leg (setScale clears pause).
   await setScale(page, SCALE);
   const home = await page.request.post('/api/planes/plane-starter/fly', { data: { destIcao: HUB } });

e2e/maintenance.spec.ts

@@ -0,0 +1,255 @@
+import type { Page } from '@playwright/test';
+import { expect, test } from '@playwright/test';
+// Real helpers (v0.39.0) — the broken-state burn math must match lib/ exactly; Playwright resolves
+// the repo's tsconfig paths, so importing beats mirroring a third copy of the formulas.
+import { initialBearingDeg } from '../lib/geo';
+import { weatherFor } from '../lib/weather';
+import { fuelAtWeighted, windBurnFactor } from '../lib/sim/movement';
+// v0.39.0 (ISS-069) — maintenance: expectations use the real balance constants + burn helpers.
+import { BROKEN_BURN_MULTIPLIER, REPAIR_COST } from '../lib/game/catalog';
+
+// v0.39.0 (ISS-069) — maintenance visible flow against the live origin: health is shown per plane in
+// the fleet list; forcing it to 0 via the set-health hook shows the "broken" pill and makes a short
+// full-tank leg burn ×1.5 more fuel (asserted with the real lib helpers); clicking Repair deducts
+// exactly REPAIR_COST, restores health and grounds the plane ("in repair" pill) until its gate
+// passes; shortening the gate via the hook brings it back to service on the next tick.
+
+const SCALE = 1000; // fastest sim speed (v0.14.0 ladder top) — keeps flights to seconds of real time
+const HUB = 'EDDF'; // must match HUB_ICAO in lib/game/seed.ts
+const STARTER = 'plane-starter';
+
+interface PlaneState {
+  id: string;
+  model: string;
+  status: 'available' | 'flying' | 'repairing';
+  fuel: number;
+  maxFuel: number;
+  locationIcao: string;
+  destIcao: string | null;
+  health: number; // v0.39.0 (ISS-069) — structural health in [0, 100]
+  repairUntilSimTime: number | null; // v0.39.0 (ISS-069) — active repair gate
+}
+
+interface CatalogEntry {
+  model: string;
+  burnPerKm: number;
+  emptyWeightKg: number;
+  maxFuel: number;
+}
+
+interface StateBody {
+  account: { cash: number };
+  simState: { clockMs: number; timeScale: number; paused: boolean };
+  planes: PlaneState[];
+  catalog: CatalogEntry[];
+}
+
+async function getState(page: Page): Promise<StateBody> {
+  const res = await page.request.get('/api/state');
+  expect(res.status()).toBe(200);
+  return (await res.json()) as StateBody;
+}
+
+// Set the time scale and VERIFY from the response that it stuck — a silent reset would otherwise
+// surface as an unexplained wait timeout. Also clears pause (ISS-041: landings slow to 1×).
+async function setScale(page: Page, scale: number): Promise<void> {
+  const res = await page.request.post('/api/sim', { data: { timeScale: scale, paused: false } });
+  expect(res.status()).toBe(200);
+  const body = (await res.json()) as { timeScale: number };
+  expect(body.timeScale, `timeScale should be ${scale} after POST /api/sim`).toBe(scale);
+}
+
+// Test hook (FLIGHT_TEST_HOOKS=1): force a plane's health and/or shorten an active repair gate.
+async function setHealth(
+  page: Page,
+  body: { planeId: string; health?: number; repairUntilMs?: number },
+): Promise<StateBody> {
+  const res = await page.request.post('/api/test/set-health', { data: body });
+  expect(res.status()).toBe(200);
+  return (await res.json()) as StateBody;
+}
+
+// Test hook (FLIGHT_TEST_HOOKS=1): top a plane's tank back to full — replaces the removed /refuel
+// endpoint (ISS-082). Reads maxFuel from the snapshot so no catalog mirror is needed.
+async function setFuelFull(page: Page, planeId: string): Promise<void> {
+  const s = await getState(page);
+  const p = s.planes.find((x) => x.id === planeId)!;
+  expect((await page.request.post('/api/test/set-fuel', { data: { planeId, fuel: p.maxFuel } })).status()).toBe(200);
+}
+
+// Mirrors haversineKm in lib/geo.ts (same formula → identical floats).
+function haversineKm(lat1: number, lon1: number, lat2: number, lon2: number): number {
+  const toRad = (d: number) => (d * Math.PI) / 180;
+  const dLat = toRad(lat2 - lat1);
+  const dLon = toRad(lon2 - lon1);
+  const a =
+    Math.sin(dLat / 2) ** 2 +
+    Math.cos(toRad(lat1)) * Math.cos(toRad(lat2)) * Math.sin(dLon / 2) ** 2;
+  return 2 * 6371 * Math.asin(Math.min(1, Math.sqrt(a)));
+}
+
+// Closest airport to EDDF from /api/airports — the short fixed leg for the broken-burn flight.
+// Returns both endpoints' coordinates so the exact-km fuel assertion can mirror lib/geo.ts.
+async function nearestToHub(page: Page): Promise<{ icao: string; lat: number; lon: number; hubLat: number; hubLon: number }> {
+  const fc = (await (await page.request.get('/api/airports')).json()) as {
+    features: Array<{ properties: { icao: string; lat: number; lon: number } }>;
+  };
+  const hub = fc.features.find((f) => f.properties.icao === HUB)!.properties;
+  let nearest = fc.features.filter((f) => f.properties.icao !== HUB)[0].properties;
+  for (const f of fc.features) {
+    if (f.properties.icao === HUB) continue;
+    if (haversineKm(hub.lat, hub.lon, f.properties.lat, f.properties.lon) < haversineKm(hub.lat, hub.lon, nearest.lat, nearest.lon)) {
+      nearest = f.properties;
+    }
+  }
+  return { icao: nearest.icao, lat: nearest.lat, lon: nearest.lon, hubLat: hub.lat, hubLon: hub.lon };
+}
+
+// Self-heal: let any in-flight leg finish and reposition plane-starter to the hub (shared DB — an
+// interrupted earlier run may have left it elsewhere or airborne). Same pattern as flyHomeViaApi in
+// right-pane.spec.ts; cargo cleanup is skipped because this flow asserts cash DELTAS, not absolutes.
+async function healStarterHome(page: Page): Promise<void> {
+  let s = await getState(page);
+  let starter = s.planes.find((p) => p.id === STARTER)!;
+  if (starter.status === 'repairing') {
+    // An interrupted run may have left it mid-repair — shorten the gate so the next tick flips it back.
+    await setHealth(page, { planeId: STARTER, health: 100, repairUntilMs: 0 });
+    await expect
+      .poll(async () => ((await getState(page)).planes.find((p) => p.id === STARTER)?.status ?? ''), {
+        timeout: 30_000,
+        message: 'waiting for the shortened repair gate to flip plane-starter back',
+      })
+      .toBe('available');
+    s = await getState(page);
+    starter = s.planes.find((p) => p.id === STARTER)!;
+  }
+  if (starter.status === 'flying' || starter.locationIcao !== HUB) {
+    // Fast-forward any leftover leg / repositioning flight (~20 s real time worst case at 1000×).
+    await setScale(page, SCALE);
+  }
+  if (starter.status === 'flying') {
+    await expect
+      .poll(async () => ((await getState(page)).planes.find((p) => p.id === STARTER)?.status ?? ''), {
+        timeout: 240_000,
+        message: 'waiting for an in-flight plane-starter to land',
+      })
+      .toBe('available');
+    s = await getState(page);
+    starter = s.planes.find((p) => p.id === STARTER)!;
+  }
+  if (starter.locationIcao !== HUB) {
+    // ISS-041: the landing above slowed the sim to 1× — setScale restores it for the return leg.
+    await setScale(page, SCALE);
+    // ISS-082: dispatch auto-refuels, so a grounded plane can always start any full-tank-flyable
+    // leg when cash allows — no top-up retry needed.
+    const flyHome = await page.request.post(`/api/planes/${STARTER}/fly`, { data: { destIcao: HUB } });
+    expect(flyHome.status()).toBe(200); // repositioning needs no package (v0.12.0 manual flight)
+    await expect
+      .poll(async () => ((await getState(page)).planes.find((p) => p.id === STARTER)?.locationIcao ?? ''), {
+        timeout: 240_000,
+        message: 'waiting for plane-starter to land back at the hub',
+      })
+      .toBe(HUB);
+  }
+}
+
+// Leave a clean starter for later spec files (shared DB, workers:1): full health and no active
+// repair gate — an interrupted run may have left the plane mid-repair or worn down.
+async function restoreStarter(page: Page): Promise<void> {
+  const s = await getState(page);
+  const starter = s.planes.find((p) => p.id === STARTER)!;
+  const body: { planeId: string; health?: number; repairUntilMs?: number } = { planeId: STARTER, health: 100 };
+  if (starter.status === 'repairing') body.repairUntilMs = 0; // shorten the active gate → flips on the next tick
+  await setHealth(page, body);
+}
+
+test.describe.configure({ mode: 'serial' }); // shared live DB — order matters within this file
+
+// On exit (success or failure): restore scale=1 / unpaused for the other specs (house convention)
+// and leave a clean starter — full health, no active repair gate.
+test.afterEach(async ({ page }) => {
+  const res = await page.request.post('/api/sim', { data: { timeScale: 1, paused: false } });
+  expect(res.status()).toBe(200);
+  await restoreStarter(page);
+});
+
+test('health shown → broken burn ×1.5 → repair grounds for 3 sim days → back to service', async ({ page }) => {
+  test.setTimeout(300_000); // self-heal + one short leg at 1000× + the shortened repair gate wait
+
+  await healStarterHome(page); // deterministic: the starter sits grounded at EDDF
+
+  // (a) Force health to 42 — snapshot AND UI show it.
+  let s = await setHealth(page, { planeId: STARTER, health: 42 });
+  expect(s.planes.find((p) => p.id === STARTER)!.health).toBe(42);
+
+  await page.goto('/');
+  const row = page.getByTestId(`plane-${STARTER}`);
+  await expect(row, 'the starter fleet row renders').toBeVisible({ timeout: 15_000 });
+  await expect(page.getByTestId(`plane-health-${STARTER}`), 'health readout shows the forced value')
+    .toContainText('42%');
+
+  // (b) Force broken — the pill shows, and a short full-tank leg burns ×1.5 more fuel.
+  s = await setHealth(page, { planeId: STARTER, health: 0 });
+  expect(s.planes.find((p) => p.id === STARTER)!.health).toBe(0);
+  await expect(page.getByTestId(`plane-broken-${STARTER}`), 'the broken pill appears')
+    .toHaveText('broken', { timeout: 15_000 });
+
+  // Full tank for the flight (ISS-082 hook — dispatch would only top up to 150% of the leg, not full)…
+  await setFuelFull(page, STARTER);
+  s = await getState(page);
+  const starter = s.planes.find((p) => p.id === STARTER)!;
+  expect(starter.fuel).toBe(starter.maxFuel);
+
+  // …then fly the short fixed leg HUB → nearest via the API (the UI under test is maintenance, not dispatch).
+  const nearest = await nearestToHub(page);
+  expect((await page.request.post(`/api/planes/${STARTER}/fly`, { data: { destIcao: nearest.icao } })).status()).toBe(200);
+  await setScale(page, SCALE);
+  await expect
+    .poll(async () => ((await getState(page)).planes.find((p) => p.id === STARTER)?.locationIcao ?? ''), {
+      timeout: 120_000,
+      message: 'waiting for the broken plane to land at the nearest airport',
+    })
+    .toBe(nearest.icao);
+
+  // Landed fuel matches the ×1.5-adjusted closed form (real lib helpers — same pattern as right-pane.spec.ts).
+  s = await getState(page);
+  const landed = s.planes.find((p) => p.id === STARTER)!;
+  const entry = s.catalog.find((e) => e.model === starter.model)!;
+  const km = haversineKm(nearest.hubLat, nearest.hubLon, nearest.lat, nearest.lon);
+  const wHub = weatherFor(HUB);
+  const burn = entry.burnPerKm * windBurnFactor(wHub.windKt, wHub.windDirDeg, initialBearingDeg(nearest.hubLat, nearest.hubLon, nearest.lat, nearest.lon));
+  expect(landed.fuel).toBeCloseTo(fuelAtWeighted(starter.maxFuel, burn * BROKEN_BURN_MULTIPLIER, entry.emptyWeightKg, entry.maxFuel, km, 1), 6);
+  // Wear clamped at 0 — the broken plane stays broken.
+  expect(landed.health).toBe(0);
+
+  // (c) Repair through the UI: exact cash drop + "in repair" pill.
+  const cashBefore = s.account.cash;
+  const repairBtn = page.getByTestId(`repair-${STARTER}`);
+  await expect(repairBtn, 'the Repair button shows for a grounded worn plane').toBeVisible({ timeout: 15_000 });
+  // The click fires the POST asynchronously — capture the endpoint's OWN response so the cash drop is
+  // checked against the exact game clock the server used (a later GET would tick further).
+  const [res] = await Promise.all([
+    page.waitForResponse((r) => r.url().includes(`/api/planes/${STARTER}/repair`), { timeout: 15_000 }),
+    repairBtn.click(),
+  ]);
+  expect(res.status()).toBe(200);
+  const post = (await res.json()) as StateBody; // full post-action snapshot at the action's clock
+  expect(post.account.cash).toBeCloseTo(cashBefore - REPAIR_COST, 6); // exactly REPAIR_COST
+  const repaired = post.planes.find((p) => p.id === STARTER)!;
+  expect(repaired.status).toBe('repairing');
+  expect(repaired.health).toBe(100); // restored to full…
+  expect(repaired.repairUntilSimTime).not.toBeNull(); // …with the gate set (3 sim days out)
+
+  await expect(page.getByTestId(`plane-repairing-${STARTER}`), 'the "in repair" pill appears')
+    .toHaveText('in repair', { timeout: 15_000 });
+
+  // (d) Shorten the gate via the hook — the plane comes back to service on the next tick.
+  await setHealth(page, { planeId: STARTER, repairUntilMs: 10_000 });
+  await setScale(page, SCALE); // fast-forward the shortened gate (each tick advances up to 2 s × scale)
+  await expect
+    .poll(async () => {
+      const p = (await getState(page)).planes.find((x) => x.id === STARTER)!;
+      return p.status === 'available' && p.health === 100 ? true : false;
+    }, { timeout: 60_000, message: 'waiting for the shortened repair gate to flip the plane back' })
+    .toBe(true);
+});

e2e/map-interactions.spec.ts

@@ -93,6 +93,14 @@ async function createPackage(page: Page, fromIcao: string, toIcao: string): Prom
   return (await created.json()) as PackageState;
 }
 
+// Test hook (FLIGHT_TEST_HOOKS=1): top the starter's tank back to full — replaces the removed /refuel
+// endpoint (ISS-082). Reads maxFuel from the snapshot so no catalog mirror is needed.
+async function setFuelFull(page: Page, planeId: string): Promise<void> {
+  const s = await getState(page);
+  const p = s.planes.find((x) => x.id === planeId)!;
+  expect((await page.request.post('/api/test/set-fuel', { data: { planeId, fuel: p.maxFuel } })).status()).toBe(200);
+}
+
 // Load a package onto plane-starter and fly it from → to via the API, then poll at
 // scale 1000 until the plane lands at `to`. Same pattern as e2e/actions.spec.ts.
 async function loadAndFly(page: Page, fromIcao: string, toIcao: string): Promise<PackageState> {
@@ -198,10 +206,8 @@ test('plane markers move while flying and the plane popup shows status + route',
     await loadAndFly(page, starterLoc, HUB);
   }
 
-  // Full tank before departure — the EDDF↔LEMD round trip burns ~4970 L of the 6300 L tank,
+  // Full tank before departure — deterministic baseline (ISS-082 hook; dispatch would auto-refuel anyway).
-  // so a partially drained plane left by an earlier spec could not make it home.
+  await setFuelFull(page, 'plane-starter');
-  const refuel = await page.request.post('/api/planes/plane-starter/refuel');
-  expect(refuel.status()).toBe(200);
 
   // 1) Load the hook-created package — a GROUNDED plane draws no route line yet.
   const pkg = await createPackage(page, HUB, DEST);

e2e/map.spec.ts

@@ -33,6 +33,11 @@ test('header shows the app version sourced from package.json', async ({ page })
   await page.goto(APP_URL);
   const header = page.getByTestId('app-header');
   await expect(header).toContainText(`v${pkg.version}`);
+  // ISS-080 (v0.40.0): the version links to the repo's CHANGELOG.md.
+  await expect(page.getByTestId('app-version')).toHaveAttribute(
+    'href',
+    'https://git.kkhost.pl/OpenCode/Flight-Ops/src/branch/master/CHANGELOG.md',
+  );
 });
 
 test('clicking an airport marker opens a popup with name and ICAO', async ({ page }) => {

e2e/panes.spec.ts

@@ -75,13 +75,10 @@ test('left pane renders wallet, reputation and the starter fleet at Frankfurt',
   await expect(page.getByTestId('left-pane').getByRole('heading', { name: 'On board', exact: true })).toHaveCount(0);
   await expect(page.getByTestId('right-pane').getByRole('heading', { name: 'On board', exact: true })).toHaveCount(0);
 
-  // ISS-035 (v0.23.0): the Refuel-to-full row moved to the left pane next to Relocate — its section
+  // ISS-082 (v0.42.0): manual refuel is gone — dispatch auto-refuels instead, so neither pane has a
-  // heading and button render here…
+  // Refuel heading or row anymore.
-  await expect(page.getByTestId('left-pane').getByRole('heading', { name: 'Refuel', exact: true })).toBeVisible();
+  await expect(page.getByTestId('left-pane').getByRole('heading', { name: 'Refuel', exact: true })).toHaveCount(0);
-  await expect(page.getByTestId('left-pane').getByTestId('market-refuel')).toBeVisible();
-  // …and neither the heading nor the row remains in the right pane.
   await expect(page.getByTestId('right-pane').getByRole('heading', { name: 'Refuel', exact: true })).toHaveCount(0);
-  await expect(page.getByTestId('right-pane').getByTestId('market-refuel')).toHaveCount(0);
 });
 
 test('sim clock ticks smoothly between polls — seconds advance without waiting for a snapshot (ISS-007)', async ({ page }) => {

e2e/queue.spec.ts

@@ -15,6 +15,7 @@ const QUEUE = 'EHAM'; // Amsterdam — a third airport, distinct from hub and de
 interface PlaneState {
   id: string;
   status: 'available' | 'flying';
+  maxFuel: number;
   locationIcao: string;
   destIcao: string | null;
   queue: string[];
@@ -69,6 +70,14 @@ async function createPackage(page: Page, fromIcao: string, toIcao: string): Prom
   return (await created.json()) as PackageState;
 }
 
+// Test hook (FLIGHT_TEST_HOOKS=1): top the starter's tank back to full — replaces the removed /refuel
+// endpoint (ISS-082). Reads maxFuel from the snapshot so no catalog mirror is needed.
+async function setFuelFull(page: Page, planeId: string): Promise<void> {
+  const s = await getState(page);
+  const p = s.planes.find((x) => x.id === planeId)!;
+  expect((await page.request.post('/api/test/set-fuel', { data: { planeId, fuel: p.maxFuel } })).status()).toBe(200);
+}
+
 // Self-heal: let any in-flight leg finish, reposition plane-starter home via the API, and abandon
 // leftover cargo so every test starts from the canonical state even after an interrupted run.
 async function flyHomeViaApi(page: Page): Promise<void> {
@@ -201,9 +210,8 @@ test('queue display + cancel via UI (ISS-043 part 2)', async ({ page }) => {
   test.setTimeout(300_000); // self-heal can take minutes after an interrupted run
   await flyHomeViaApi(page); // deterministic: the starter sits grounded at EDDF
 
-  // Full tank before departure — keeps the long EDDF→LEMD leg fuel-feasible (same as tests 2 & 3).
+  // Full tank before departure — deterministic baseline (ISS-082 hook; dispatch would auto-refuel anyway).
-  const refuel = await page.request.post('/api/planes/plane-starter/refuel');
+  await setFuelFull(page, 'plane-starter');
-  expect(refuel.status()).toBe(200);
 
   const pkg = await createPackage(page, HUB, DEST);
 
@@ -272,9 +280,8 @@ test('dotted queue line renders the queued path on the map (ISS-043 part 2)', as
   test.setTimeout(300_000); // self-heal + one flight at scale 1000 + fly-home cleanup
   await flyHomeViaApi(page);
 
-  // Full tank before departure — keeps the state canonical for whatever the cleanup does.
+  // Full tank before departure — keeps the state canonical for whatever the cleanup does (ISS-082 hook).
-  const refuel = await page.request.post('/api/planes/plane-starter/refuel');
+  await setFuelFull(page, 'plane-starter');
-  expect(refuel.status()).toBe(200);
 
   // Load + queue + fly via the API: a package EDDF→LEMD, one queued leg LEMD→EHAM (works while
   // grounded — part 1), then start leg 1. The dotted line must show ONLY dest → queue[0].
@@ -350,13 +357,70 @@ test('dotted queue line renders the queued path on the map (ISS-043 part 2)', as
   }).toBe(HUB);
 });
 
+test('grounded plane with a pre-built queue draws its dotted route from its airport (ISS-077)', async ({ page }) => {
+  test.setTimeout(300_000); // self-heal + map assertions only — no flight in this test
+  await flyHomeViaApi(page); // deterministic: the starter sits grounded at EDDF
+
+  await page.goto('/');
+  await waitForAirportCount(page);
+
+  // Pre-build a two-leg route while GROUNDED via the raw API (queuing is allowed from any state,
+  // ISS-043 part 1) — no package or flight needed. The dotted line must chain HUB → DEST → QUEUE.
+  const q1 = await page.request.post('/api/planes/plane-starter/queue', { data: { destIcao: DEST } });
+  expect(q1.status()).toBe(200);
+  const q2 = await page.request.post('/api/planes/plane-starter/queue', { data: { destIcao: QUEUE } });
+  expect(q2.status()).toBe(200);
+
+  // All chain endpoints must be in-viewport for queryRenderedFeatures to see them.
+  await fitToAirports(page, [HUB, DEST, QUEUE]);
+
+  const hubLL = await airportLonLat(page, HUB);
+  const destLL = await airportLonLat(page, DEST);
+  const queueLL = await airportLonLat(page, QUEUE);
+  const near = (a: [number, number], b: [number, number]) =>
+    Math.abs(a[0] - b[0]) <= QUEUE_ROUTE_EPS_DEG && Math.abs(a[1] - b[1]) <= QUEUE_ROUTE_EPS_DEG;
+
+  await expect.poll(async () => {
+    const feats = (await renderedFeatures(page, ['queue-routes'])) as Array<{
+      properties?: Record<string, unknown>;
+      geometry?: { type: string; coordinates: [number, number][] };
+    }>;
+    // Filter to real LineString segments — keeps this poll callback total. "None yet" → keep polling.
+    const segs = feats.filter(
+      (f): f is { properties?: Record<string, unknown>; geometry: { type: 'LineString'; coordinates: [number, number][] } } =>
+        !!f.geometry && f.geometry.type === 'LineString' && Array.isArray(f.geometry.coordinates) && f.geometry.coordinates.length >= 2,
+    );
+    if (!segs.length) return false;
+    // The chain HUB → DEST → QUEUE may be clipped into per-tile segments — check across all of them:
+    // some segment STARTS within EPS of the hub (the plane's airport, NOT a flight destination)…
+    const startsAtHub = segs.some((f) => near(f.geometry.coordinates[0], hubLL));
+    // …some ENDS within EPS of the last queued airport…
+    const endsAtQueue = segs.some((f) => {
+      const c = f.geometry.coordinates;
+      return near(c[c.length - 1], queueLL);
+    });
+    // …and the chain passes THROUGH the first queued airport — an interior joint point survives in
+    // whichever tile contains it (not guaranteed to be a segment endpoint after clipping).
+    const passesThroughDest = segs.some((f) => f.geometry.coordinates.some((c) => near(c, destLL)));
+    // Every rendered feature belongs to plane-starter.
+    const ownedByStarter = feats.every((f) => f.properties?.planeId === 'plane-starter');
+    return startsAtHub && endsAtQueue && passesThroughDest && ownedByStarter;
+  }, { timeout: 15_000, message: `waiting for the dotted queue line ${HUB} → ${DEST} → ${QUEUE}` }).toBe(true);
+
+  // Cleanup: cancel both queued legs (index 0 twice — each cancel shifts the rest down) so the
+  // starter stays grounded at HUB with an empty queue. No flight happened, nothing else to reset.
+  const c1 = await page.request.post('/api/planes/plane-starter/queue/cancel', { data: { index: 0 } });
+  expect(c1.status()).toBe(200);
+  const c2 = await page.request.post('/api/planes/plane-starter/queue/cancel', { data: { index: 0 } });
+  expect(c2.status()).toBe(200);
+});
+
 test('landing auto-starts the next queued leg (ISS-043 chain end-to-end)', async ({ page }) => {
   test.setTimeout(300_000); // self-heal + two chained legs at scale 1000
   await flyHomeViaApi(page);
 
-  // Full tank so fuel covers the chained return leg (same feasibility rule as /fly).
+  // Full tank for a deterministic baseline — the engine auto-chains (and auto-refuels, ISS-082) the return leg regardless.
-  const refuel = await page.request.post('/api/planes/plane-starter/refuel');
+  await setFuelFull(page, 'plane-starter');
-  expect(refuel.status()).toBe(200);
 
   // Package EDDF→LEMD + a queued return leg LEMD→EDDF, then start leg 1.
   const pkg = await createPackage(page, HUB, DEST);

e2e/relocation.spec.ts

@@ -15,7 +15,7 @@ const HUB = 'EDDF'; // Frankfurt Main — the seeded starter plane's home base (
 const POPUP_AIRPORT = { icao: 'LFRS', lon: -1.61073, lat: 47.153198 };
 
 interface StateBody {
-  planes: Array<{ id: string; status: string; locationIcao: string; destIcao: string | null }>;
+  planes: Array<{ id: string; status: string; maxFuel: number; locationIcao: string; destIcao: string | null }>;
 }
 
 async function getState(page: Page): Promise<StateBody> {
@@ -24,6 +24,14 @@ async function getState(page: Page): Promise<StateBody> {
   return (await res.json()) as StateBody;
 }
 
+// Test hook (FLIGHT_TEST_HOOKS=1): top the starter's tank back to full — replaces the removed /refuel
+// endpoint (ISS-082). Reads maxFuel from the snapshot so no catalog mirror is needed.
+async function setFuelFull(page: Page, planeId: string): Promise<void> {
+  const s = await getState(page);
+  const p = s.planes.find((x) => x.id === planeId)!;
+  expect((await page.request.post('/api/test/set-fuel', { data: { planeId, fuel: p.maxFuel } })).status()).toBe(200);
+}
+
 async function postSim(page: Page, body: Record<string, unknown>): Promise<void> {
   const res = await page.request.post('/api/sim', { data: body });
   expect(res.ok()).toBeTruthy();
@@ -96,10 +104,8 @@ test('left pane Relocate section relocates a grounded plane', async ({ page }) =
   test.setTimeout(300_000); // self-heal (worst case ~20 s at 1000×) + one short leg
   await flyHomeViaApi(page);
 
-  // Full tank before departure — a partially drained plane left by an earlier spec could not
+  // Full tank before departure — deterministic baseline (ISS-082 hook; dispatch would auto-refuel anyway).
-  // afford the cleanup round trip.
+  await setFuelFull(page, 'plane-starter');
-  const refuel = await page.request.post('/api/planes/plane-starter/refuel');
-  expect(refuel.ok()).toBeTruthy();
 
   const nearest = await nearestToHub(page);
 
@@ -130,8 +136,8 @@ test('airport popup offers Relocate options for grounded planes', async ({ page
   test.setTimeout(300_000); // self-heal (worst case ~20 s at 1000×) + one leg to LFRS
   await flyHomeViaApi(page);
 
-  const refuel = await page.request.post('/api/planes/plane-starter/refuel');
+  // Full tank before departure — deterministic baseline (ISS-082 hook; dispatch would auto-refuel anyway).
-  expect(refuel.ok()).toBeTruthy();
+  await setFuelFull(page, 'plane-starter');
 
   await page.goto('/');
 

e2e/right-pane.spec.ts

@@ -4,9 +4,9 @@ import { expect, test } from '@playwright/test';
 // the repo's tsconfig paths, so importing beats mirroring a third copy of the formulas.
 import { initialBearingDeg } from '../lib/geo';
 import { weatherFor } from '../lib/weather';
-import { windBurnFactor } from '../lib/sim/movement';
+import { fuelAtWeighted, windBurnFactor } from '../lib/sim/movement';
 // v0.38.0 (ISS-072) — reputation discounts: expectations computed from the LIVE snapshot's rep with the real helpers.
-import { FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT, MAX_PLANE_DISCOUNT, PLANE_DISCOUNT_PER_REP, repRate } from '../lib/game/catalog';
+import { conditionBurnMultiplier, FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT, MAX_PLANE_DISCOUNT, PLANE_DISCOUNT_PER_REP, repRate } from '../lib/game/catalog';
 import { STARTING_REPUTATION } from '../lib/game/seed';
 
 // v0.12.0 — right Jobs & Market pane against the live origin: open packages render with
@@ -14,8 +14,8 @@ import { STARTING_REPUTATION } from '../lib/game/seed';
 // (moved to the left pane in v0.20.0, ISS-021) shows loaded packages with fly-to-destination +
 // abandon buttons (penalty preview from the same
 // formula as the server); flying planes show their current leg; market buy/sell previews match
-// the catalog + economy constants exposed in /api/state, and the Refuel-to-full row (moved to the
+// the catalog + economy constants exposed in /api/state, and dispatch auto-refuels a low tank to
-// left pane in v0.23.0, ISS-035) deducts exactly its cost. Packages are created via
+// 150% of the leg requirement at exactly its rep-discounted cost (ISS-082). Packages are created via
 // POST /api/test/create-package (FLIGHT_TEST_HOOKS=1), same pattern as e2e/actions.spec.ts.
 
 const SCALE = 1000; // fastest sim speed (v0.14.0 ladder top) — keeps flights to seconds of real time
@@ -27,6 +27,7 @@ interface PlaneState {
   status: 'available' | 'flying';
   fuel: number;
   maxFuel: number;
+  health: number; // v0.39.0 (ISS-069) — feeds conditionBurnMultiplier in the auto-refuel math
   locationIcao: string;
   destIcao: string | null;
 }
@@ -112,7 +113,8 @@ function penaltyFor(reward: number, createdSimTime: number, deadlineSimTime: num
 }
 
 // Closest airport to EDDF from /api/airports → shortest possible arrival time at scale 1000.
-async function nearestToHub(page: Page): Promise<{ icao: string; lat: number; lon: number }> {
+// Returns both endpoints' coordinates so exact-km fuel assertions can mirror lib/geo.ts.
+async function nearestToHub(page: Page): Promise<{ icao: string; lat: number; lon: number; hubLat: number; hubLon: number }> {
   const fc = (await (await page.request.get('/api/airports')).json()) as {
     features: Array<{ properties: { icao: string; lat: number; lon: number } }>;
   };
@@ -124,38 +126,7 @@ async function nearestToHub(page: Page): Promise<{ icao: string; lat: number; lo
       nearest = f.properties;
     }
   }
-  return nearest;
+  return { ...nearest, hubLat: hub.lat, hubLon: hub.lon };
-}
-
-// Farthest airport from EDDF whose leg still FITS A FULL TANK — the longest flyable leg (v0.16.0
-// refuel-for-flight test). The dataset's absolute farthest can exceed the aircraft's range, so a
-// full-tank fly there would rightly 409; this test wants a long-but-flyable leg instead. Wind-
-// adjusted (v0.36.0): BOTH directions must fit — the outbound is flown from a full tank and the
-// return leg is what the forFlight refuel below buys, which also 409s if it doesn't fit.
-async function farthestFlyableToHub(
-  page: Page,
-  entry: CatalogEntry,
-): Promise<{ icao: string; lat: number; lon: number; d: number; hubLat: number; hubLon: number }> {
-  const fc = (await (await page.request.get('/api/airports')).json()) as {
-    features: Array<{ properties: { icao: string; lat: number; lon: number } }>;
-  };
-  const hub = fc.features.find((f) => f.properties.icao === HUB)!.properties;
-  const wHub = weatherFor(HUB);
-  let farthest: { icao: string; lat: number; lon: number; d: number } | null = null;
-  for (const f of fc.features) {
-    if (f.properties.icao === HUB) continue;
-    const d = haversineKm(hub.lat, hub.lon, f.properties.lat, f.properties.lon);
-    const wDest = weatherFor(f.properties.icao);
-    const outBurn = entry.burnPerKm * windBurnFactor(wHub.windKt, wHub.windDirDeg, initialBearingDeg(hub.lat, hub.lon, f.properties.lat, f.properties.lon));
-    if (requiredFuelFor(outBurn, entry.emptyWeightKg, entry.maxFuel, d) > entry.maxFuel) continue; // beyond range
-    const backBurn = entry.burnPerKm * windBurnFactor(wDest.windKt, wDest.windDirDeg, initialBearingDeg(f.properties.lat, f.properties.lon, hub.lat, hub.lon));
-    if (requiredFuelFor(backBurn, entry.emptyWeightKg, entry.maxFuel, d) > entry.maxFuel) continue; // return leg wouldn't fit a full tank either
-    if (!farthest || d > farthest.d) {
-      farthest = { icao: f.properties.icao, lat: f.properties.lat, lon: f.properties.lon, d };
-    }
-  }
-  if (!farthest) throw new Error('no full-tank-flyable airport found in the dataset');
-  return { ...farthest, hubLat: hub.lat, hubLon: hub.lon };
 }
 
 // Mirrors lib/sim/movement.ts (v0.16.0): fuel required to cover distanceKm arriving empty —
@@ -184,7 +155,11 @@ async function createPackage(page: Page, fromIcao: string, toIcao: string, deadl
 
 // Self-heal: let any in-flight leg finish, then reposition plane-starter home via the API.
 async function flyHomeViaApi(page: Page): Promise<void> {
-  const s0 = await getState(page);
+  // v0.39.0 (ISS-069): wear accumulates across the shared CI DB — restore full health and clear any
+  // active repair gate from an interrupted run before the steps below act on the starter, so the
+  // farthest-flyable picker and fuel pins never see a worn or broken plane.
+  expect((await page.request.post('/api/test/set-health', { data: { planeId: 'plane-starter', health: 100, repairUntilMs: 0 } })).status()).toBe(200);
+  const s0 = await getState(page); // ticks — a shortened gate flips the plane back to available here
   const starter = s0.planes.find((p) => p.id === 'plane-starter')!;
   if (starter.status === 'flying' || starter.locationIcao !== HUB) {
     // Fast-forward any leftover leg / repositioning flight (~20 s real time worst case at 1000×).
@@ -200,14 +175,10 @@ async function flyHomeViaApi(page: Page): Promise<void> {
   }
   if (starter.locationIcao !== HUB) {
     // ISS-041: the landing above paused the sim — setScale clears pause so the return leg
-    // fast-forwards instead of taking real-time hours.
+    // fast-forwards instead of taking real-time hours. ISS-082: dispatch auto-refuels, so a
+    // grounded plane can always start any full-tank-flyable leg when cash allows — no top-up retry needed.
     await setScale(page, SCALE);
-    let flyHome = await page.request.post('/api/planes/plane-starter/fly', { data: { destIcao: HUB } });
+    const flyHome = await page.request.post('/api/planes/plane-starter/fly', { data: { destIcao: HUB } });
-    if (!flyHome.ok()) {
-      // A long outbound leg can leave the tank too empty for the return — top up and retry.
-      expect((await page.request.post('/api/planes/plane-starter/refuel')).status()).toBe(200);
-      flyHome = await page.request.post('/api/planes/plane-starter/fly', { data: { destIcao: HUB } });
-    }
     expect(flyHome.status()).toBe(200); // repositioning needs no package (v0.12.0 manual flight)
     await expect
       .poll(async () => (await getState(page)).planes.find((p) => p.id === 'plane-starter')?.locationIcao === HUB, {
@@ -357,7 +328,7 @@ test('on-board list: fly-to-destination + abandon with penalty preview; flying p
     .toBe(true);
 });
 
-test('market buy/sell render with previews from the catalog in /api/state; left-pane Refuel deducts exactly', async ({ page }) => {
+test('market buy/sell render with previews from the catalog in /api/state', async ({ page }) => {
   test.setTimeout(300_000); // self-heal can take minutes after an interrupted run
   await flyHomeViaApi(page); // grounded starter at EDDF (tank partial after the previous test's flight)
 
@@ -393,117 +364,80 @@ test('market buy/sell render with previews from the catalog in /api/state; left-
   await page.getByTestId('market-sell-plane').selectOption('plane-starter', { timeout: 15_000 });
   const payout = Math.round(entry.price * body.sellFraction * 100) / 100;
   await expect(page.getByTestId('market-sell-payout')).toContainText(eur(payout));
-
-  // ISS-035 (v0.23.0): the Refuel-to-full row now lives in the LEFT pane next to Relocate — same global testids.
-  await expect(page.getByTestId('left-pane').getByTestId('market-refuel')).toBeVisible({ timeout: 15_000 });
-
-  // Refuel through the pane: the flight genuinely burned fuel…
-  if (starter.fuel < starter.maxFuel) {
-    // v0.38.0 (ISS-072): rep-scaled cost — same formula as the server's refuelPlane 'full'.
-    const fuelRate = repRate(body.account.reputation, FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT);
-    const expectedCost = Math.round((starter.maxFuel - starter.fuel) * body.fuelPricePerL * (1 - fuelRate) * 100) / 100;
-    const cashBefore = body.account.cash;
-
-    // …the refuel picker lists it, the preview matches the exact cost, and the click deducts it.
-    await expect(page.getByTestId('market-refuel-plane')).toBeVisible({ timeout: 15_000 });
-    await page.getByTestId('market-refuel-plane').selectOption('plane-starter');
-    await expect(page.getByTestId('market-refuel-cost')).toContainText(eur(expectedCost));
-    await page.getByTestId('market-refuel').click();
-
-    // Cash decreased by exactly the expected cost and the tank is full (server truth).
-    await expect
-      .poll(async () => {
-        const b = await getState(page);
-        return Math.abs(b.account.cash - (cashBefore - expectedCost)) < 0.001;
-      }, { timeout: 15_000, message: 'waiting for the refuel cost to land in /api/state' })
-      .toBe(true);
-    const after = await getState(page);
-    expect(after.planes.find((p) => p.id === 'plane-starter')!.fuel).toBe(starter.maxFuel);
-  }
 });
 
-test('on-board row Refuel buys 150% of the weather-adjusted leg requirement; left-pane button says "Refuel to full"', async ({ page }) => {
+// ISS-082 (v0.42.0): manual refuel is gone — dispatch auto-refuels instead. This test pins the new
-  test.setTimeout(300_000); // self-heal + one long flight each way at scale 1000
+// behavior end-to-end: drop a grounded starter to low fuel via the hook, fly a leg, and assert the
+// cash delta equals the EXACT rep-discounted top-up cost (computed from the snapshot + real lib
+// helpers) while the post-flight landed fuel matches the weighted burn from the topped start value.
+test('dispatch auto-refuels: a low tank tops up to 150% of the leg requirement and deducts exactly', async ({ page }) => {
+  test.setTimeout(300_000); // self-heal + one short flight each way at scale 1000
   await flyHomeViaApi(page);
 
   const body = await getState(page);
   const entry = body.catalog.find((e) => e.model === 'atr72')!;
 
-  // Deterministic baseline: a full tank.
+  // Drop the grounded starter to a low, deterministic fuel level via the test hook — well below the
-  expect((await page.request.post('/api/planes/plane-starter/refuel')).status()).toBe(200);
+  // 150%-of-requirement target even for the shortest dataset leg (EDFH, ~93 km), so a top-up is guaranteed.
+  const LOW_FUEL = 50;
+  expect((await page.request.post('/api/test/set-fuel', { data: { planeId: 'plane-starter', fuel: LOW_FUEL } })).status()).toBe(200);
 
-  // Longest FLYABLE leg from the hub (fits a full tank) — long enough that 150% of its requirement
+  // Nearest airport to the hub → short leg, fast at scale 1000.
-  // exceeds what's left on arrival.
+  const nearest = await nearestToHub(page);
-  const farthest = await farthestFlyableToHub(page, entry);
+  const pre = await getState(page);
-  const pkg1 = await createPackage(page, HUB, farthest.icao, 24 * 3_600_000);
+  const starter = pre.planes.find((p) => p.id === 'plane-starter')!;
-  expect((await page.request.post(`/api/packages/${pkg1.id}/load`, { data: { planeId: 'plane-starter' } })).status()).toBe(200);
+  expect(starter.fuel).toBe(LOW_FUEL); // the hook stuck
 
-  // Fly there (delivers pkg1 on arrival) — the tank is now partial.
+  // Expected top-up from the snapshot constants — mirrors flyPlane's math (lib/game/actions.ts):
-  expect((await page.request.post('/api/planes/plane-starter/fly', { data: { destIcao: farthest.icao } })).status()).toBe(200);
+  // wind-adjusted requirement × condition multiplier, 150% margin capped at tank capacity.
+  const km = haversineKm(nearest.hubLat, nearest.hubLon, nearest.lat, nearest.lon);
+  const wHub = weatherFor(HUB);
+  const required = requiredFuelFor(
+    entry.burnPerKm * windBurnFactor(wHub.windKt, wHub.windDirDeg, initialBearingDeg(nearest.hubLat, nearest.hubLon, nearest.lat, nearest.lon)) * conditionBurnMultiplier(starter.health),
+    entry.emptyWeightKg,
+    entry.maxFuel,
+    km,
+  );
+  const target = Math.min(entry.maxFuel, Math.max(LOW_FUEL, required * 1.5)); // ISS-082: 150% margin, capped at tank capacity
+  const liters = Math.max(0, target - LOW_FUEL);
+  expect(liters).toBeGreaterThan(0); // the low tank genuinely needs a top-up
+  const fuelRate = repRate(pre.account.reputation, FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT);
+  const expectedCost = Math.round(liters * pre.fuelPricePerL * (1 - fuelRate) * 100) / 100;
+  const cashBefore = pre.account.cash;
+
+  // Dispatch via the API — the response snapshot is authoritative at the action's clock.
+  const flyRes = await page.request.post('/api/planes/plane-starter/fly', { data: { destIcao: nearest.icao } });
+  expect(flyRes.status()).toBe(200); // auto-refuel made the low tank flyable…
+  const post = (await flyRes.json()) as StateBody;
+  expect(post.planes.find((p) => p.id === 'plane-starter')!.fuel).toBeCloseTo(target, 6); // …departing with exactly the topped level
+  expect(post.account.cash).toBeCloseTo(cashBefore - expectedCost, 6); // …at exactly the rep-discounted cost
+
+  // Fast-forward to arrival; the landed fuel is the weighted burn from the TOPPED start value.
   await setScale(page, SCALE);
   await expect
     .poll(async () => {
       const b = await getState(page);
       const p = b.planes.find((x) => x.id === 'plane-starter');
-      return !!p && p.status === 'available' && p.locationIcao === farthest.icao;
+      return !!p && p.status === 'available' && p.locationIcao === nearest.icao;
-    }, { timeout: 240_000, message: `waiting for arrival at ${farthest.icao} (scale 1000)` })
+    }, { timeout: 120_000, message: `waiting for arrival at ${nearest.icao} (scale 1000)` })
     .toBe(true);
 
-  // New work at the far end: a package back to the hub — its leg is exactly what we refuel for.
+  const landed = await getState(page);
-  const pkg2 = await createPackage(page, farthest.icao, HUB, 24 * 3_600_000);
+  expect(landed.planes.find((p) => p.id === 'plane-starter')!.fuel).toBeCloseTo(
-  expect((await page.request.post(`/api/packages/${pkg2.id}/load`, { data: { planeId: 'plane-starter' } })).status()).toBe(200);
+    fuelAtWeighted(target, entry.burnPerKm * windBurnFactor(wHub.windKt, wHub.windDirDeg, initialBearingDeg(nearest.hubLat, nearest.hubLon, nearest.lat, nearest.lon)) * conditionBurnMultiplier(starter.health), entry.emptyWeightKg, entry.maxFuel, km, 1),
-
+    6,
-  // Expected "150% of the requirement" from the snapshot constants (mirrors requiredFuelFor in
-  // lib/sim/movement.ts, wind-adjusted per v0.36.0 — departure weather at the far end vs heading home).
-  const pre = await getState(page);
-  const fuelBefore = pre.planes.find((p) => p.id === 'plane-starter')!.fuel;
-  const cashBefore = pre.account.cash;
-  const km = haversineKm(farthest.hubLat, farthest.hubLon, farthest.lat, farthest.lon); // symmetric: hub ↔ far end
-  const wFar = weatherFor(farthest.icao);
-  const required = requiredFuelFor(
-    entry.burnPerKm * windBurnFactor(wFar.windKt, wFar.windDirDeg, initialBearingDeg(farthest.lat, farthest.lon, farthest.hubLat, farthest.hubLon)),
-    entry.emptyWeightKg,
-    entry.maxFuel,
-    km,
   );
-  const target = Math.min(entry.maxFuel, required * 1.5); // ISS-071: 150% margin, capped at tank capacity
-  const liters = Math.max(0, target - fuelBefore);
-  expect(liters).toBeGreaterThan(0); // the long leg genuinely needs more than what's left
-  // v0.38.0 (ISS-072): rep-scaled cost — same formula as the server's refuelPlane 'forFlight'.
-  const fuelRate = repRate(pre.account.reputation, FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT);
-  const expectedCost = Math.round(liters * pre.fuelPricePerL * (1 - fuelRate) * 100) / 100;
 
-  await page.goto('/');
+  // Restore: fly home (auto-refuel covers the return leg) and top the tank back up for later specs.
-  const refuelBtn = page.getByTestId(`refuel-for-${pkg2.id}`);
-  await expect(refuelBtn, 'row Refuel button appears for the loaded package').toBeVisible({ timeout: 15_000 });
-  // Capture the endpoint's OWN response — the full post-action snapshot at the action's clock.
-  const [res] = await Promise.all([
-    page.waitForResponse((r) => r.url().includes(`/api/planes/plane-starter/refuel`), { timeout: 15_000 }),
-    refuelBtn.click(),
-  ]);
-  expect(res.status()).toBe(200);
-  const post = (await res.json()) as StateBody;
-
-  // Cash dropped by exactly L × price and fuel rose by exactly L.
-  expect(post.account.cash).toBeCloseTo(cashBefore - expectedCost, 6);
-  expect(post.planes.find((p) => p.id === 'plane-starter')!.fuel).toBeCloseTo(fuelBefore + liters, 6);
-
-  // Left pane (moved from the market in v0.23.0, ISS-035): the fill-up button is labeled "Refuel to full" (testid unchanged).
-  await expect(page.getByTestId('market-refuel')).toHaveText('Refuel to full');
-
-  // Restore: fly home — pkg2's destination IS the hub, so it delivers on arrival. The tank holds
-  // 150% of the leg requirement (or a full tank), so the return is comfortably feasible. ISS-041:
-  // the far-end arrival above paused the sim, so re-set SCALE for this leg (setScale clears pause).
   await setScale(page, SCALE);
   expect((await page.request.post('/api/planes/plane-starter/fly', { data: { destIcao: HUB } })).status()).toBe(200);
   await expect
     .poll(async () => (await getState(page)).planes.find((p) => p.id === 'plane-starter')?.locationIcao === HUB, {
-      timeout: 240_000,
+      timeout: 120_000,
       message: 'waiting for plane-starter to land back at the hub',
     })
     .toBe(true);
-  // Top the tank back up so later specs start with a full tank.
+  expect((await page.request.post('/api/test/set-fuel', { data: { planeId: 'plane-starter', fuel: entry.maxFuel } })).status()).toBe(200);
-  expect((await page.request.post('/api/planes/plane-starter/refuel')).status()).toBe(200);
 });
 
 test('Ignore removes an open job from the list permanently (ISS-047 part B)', async ({ page }) => {

e2e/slow-on-landing.spec.ts

@@ -80,12 +80,9 @@ async function flyHomeViaApi(page: Page): Promise<void> {
     // ISS-057: the landing above slowed the sim to 1× — setScale restores 1000× (and records it as
     // lastSelectedTimeScale) so the return leg fast-forwards instead of taking real-time hours.
     await setScale(page, SCALE);
-    let flyHome = await page.request.post(`/api/planes/${plane.id}/fly`, { data: { destIcao: HUB } });
+    // ISS-082: dispatch auto-refuels, so a grounded plane can always start any full-tank-flyable
-    if (!flyHome.ok()) {
+    // leg when cash allows — no top-up retry needed.
-      // A long outbound leg can leave the tank too empty for the return — top up and retry.
+    const flyHome = await page.request.post(`/api/planes/${plane.id}/fly`, { data: { destIcao: HUB } });
-      expect((await page.request.post(`/api/planes/${plane.id}/refuel`)).status()).toBe(200);
-      flyHome = await page.request.post(`/api/planes/${plane.id}/fly`, { data: { destIcao: HUB } });
-    }
     expect(flyHome.ok()).toBeTruthy(); // repositioning needs no package (v0.12.0 manual flight)
     await expect.poll(async () => ((await getState(page)).planes.find((p) => p.id === 'plane-starter')!.locationIcao), { timeout: 240_000 }).toBe(HUB);
   }

e2e/two-planes.spec.ts

@@ -5,15 +5,13 @@ import { expect, test } from '@playwright/test';
 import { initialBearingDeg } from '../lib/geo';
 import { weatherFor } from '../lib/weather';
 import { windBurnFactor } from '../lib/sim/movement';
-// v0.38.0 (ISS-072) — reputation discounts: expectations computed from the LIVE snapshot's rep with the real helpers.
-import { FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT, repRate } from '../lib/game/catalog';
 
 // v0.31.0 — ISS-055: gameplay with TWO planes in the fleet. The reported bug ("can't load cargo
 // if both planes are on the same airport") was UX-only: LoadControls' multi-plane path rendered a
 // greyed-out Load button until a plane was picked from the dropdown, while the single-plane path
 // is one-click. v0.31.0 preselects the first eligible plane (components/RightPane.tsx), and this
 // spec covers every two-plane flow: load (preselect + picker), parallel flights with the ISS-057
-// slow/resume semantics, refuel, relocate, per-plane queues (scoped testids) and sell.
+// slow/resume semantics, relocate, per-plane queues (scoped testids) and sell.
 //
 // Each test buys its own second plane via the UI (after a cash grant from the new
 // POST /api/test/add-cash hook — ATR €200k vs the €20k starting balance); beforeEach/afterEach
@@ -171,6 +169,14 @@ async function addCash(page: Page, amount?: number): Promise<StateBody> {
   return (await res.json()) as StateBody;
 }
 
+// Test hook (FLIGHT_TEST_HOOKS=1): top a plane's tank back to full — replaces the removed /refuel
+// endpoint (ISS-082). Reads maxFuel from the snapshot so no catalog mirror is needed.
+async function setFuelFull(page: Page, planeId: string): Promise<void> {
+  const s = await getState(page);
+  const p = s.planes.find((x) => x.id === planeId)!;
+  expect((await page.request.post('/api/test/set-fuel', { data: { planeId, fuel: p.maxFuel } })).status()).toBe(200);
+}
+
 // Buy a second ATR through the UI (Planes market tab) and return its id — discovered in /api/state
 // as the plane that isn't plane-starter (bought planes get random UUIDs, no stable name).
 async function buySecondPlaneViaUi(page: Page): Promise<string> {
@@ -244,13 +250,10 @@ async function healPlaneHome(page: Page, planeId: string): Promise<void> {
   }
   if (p.locationIcao !== HUB) {
     // ISS-057: the landing above slowed the sim to 1× — setScale restores 1000× for the return leg.
+    // ISS-082: dispatch auto-refuels, so a grounded plane can always start any full-tank-flyable
+    // leg when cash allows — no top-up retry needed.
     await setScale(page, SCALE);
-    let flyHome = await page.request.post(`/api/planes/${planeId}/fly`, { data: { destIcao: HUB } });
+    const flyHome = await page.request.post(`/api/planes/${planeId}/fly`, { data: { destIcao: HUB } });
-    if (flyHome.status() === 409) {
-      // A long outbound leg can leave the tank too empty for the return — top up and retry.
-      expect((await page.request.post(`/api/planes/${planeId}/refuel`)).status()).toBe(200);
-      flyHome = await page.request.post(`/api/planes/${planeId}/fly`, { data: { destIcao: HUB } });
-    }
     expect(flyHome.status()).toBe(200);
     await expect
       .poll(async () => ((await getState(page)).planes.find((x) => x.id === planeId)?.locationIcao ?? ''), {
@@ -275,8 +278,11 @@ async function sellNonStarters(page: Page): Promise<void> {
 // Canonical start state for every test: fleet of exactly one plane (the starter), grounded at EDDF,
 // no cargo on board — even after an interrupted previous run.
 async function resetFleet(page: Page): Promise<void> {
+  // v0.39.0 (ISS-069): wear accumulates across the shared CI DB — restore full health and clear any
+  // active repair gate before healing, so the farthest-flyable picker never sees a worn/broken starter.
+  expect((await page.request.post('/api/test/set-health', { data: { planeId: STARTER, health: 100, repairUntilMs: 0 } })).status()).toBe(200);
   await sellNonStarters(page);
-  await healPlaneHome(page, STARTER);
+  await healPlaneHome(page, STARTER); // the tick inside its getState flips a shortened gate back to available
   await abandonLeftoverCargo(page, STARTER);
 }
 
@@ -347,8 +353,8 @@ test('two planes fly in parallel; the last landing slows to 1× and the next dis
   const secondId = await buySecondPlaneViaUi(page);
 
   // Full tanks for both — the starter's may be partial from an earlier run.
-  expect((await page.request.post(`/api/planes/${STARTER}/refuel`)).status()).toBe(200);
+  await setFuelFull(page, STARTER);
-  expect((await page.request.post(`/api/planes/${secondId}/refuel`)).status()).toBe(200);
+  await setFuelFull(page, secondId);
 
   // Two very different leg lengths: the starter takes the SHORTEST hop, the second plane the longest
   // full-tank-flyable one — their landings are separated by hours of game time and can never fall on
@@ -399,8 +405,8 @@ test('two planes fly in parallel; the last landing slows to 1× and the next dis
   expect(landed.packages.find((p) => p.id === pkgA.id)?.status).toBe('delivered');
   expect(landed.packages.find((p) => p.id === pkgB.id)?.status).toBe('delivered');
 
-  // The outbound to the range edge left the tank nearly empty — top up for the return leg.
+  // The outbound to the range edge left the tank nearly empty — top it back up (ISS-082 hook).
-  expect((await page.request.post(`/api/planes/${secondId}/refuel`)).status()).toBe(200);
+  await setFuelFull(page, secondId);
 
   // Resume semantics: with the starter still grounded, dispatching the second plane does NOT resume…
   const flyB2 = await page.request.post(`/api/planes/${secondId}/fly`, { data: { destIcao: HUB } });
@@ -415,64 +421,8 @@ test('two planes fly in parallel; the last landing slows to 1× and the next dis
   expect(body.simState.timeScale, 'the last grounded plane resumes lastSelectedTimeScale').toBe(SCALE); // setScale posted 1000
 });
 
-test('refuel section lists both planes; refueling one tops only its tank', async ({ page }) => {
+// ISS-082 (v0.42.0): the "refuel section lists both planes" test is gone with the manual refuel UI —
-  test.setTimeout(300_000); // self-heal + two short hops at scale 1000
+// its absence is pinned in e2e/panes.spec.ts instead.
-  const secondId = await buySecondPlaneViaUi(page);
-
-  // Partial tanks: a short hop each, to different destinations.
-  const [a, b] = await twoNearestToHub(page);
-  expect((await page.request.post(`/api/planes/${STARTER}/refuel`)).status()).toBe(200);
-  expect((await page.request.post(`/api/planes/${secondId}/refuel`)).status()).toBe(200);
-  expect((await page.request.post(`/api/planes/${STARTER}/fly`, { data: { destIcao: a.icao } })).status()).toBe(200);
-  expect((await page.request.post(`/api/planes/${secondId}/fly`, { data: { destIcao: b.icao } })).status()).toBe(200);
-
-  // Fast-forward to the first landing, restore speed (ISS-057 slows on any landing), then wait for both.
-  await setScale(page, SCALE);
-  await expect
-    .poll(async () => ((await getState(page)).planes.some((p) => p.status === 'available')), {
-      timeout: 240_000,
-      message: 'waiting for the first plane to land',
-    })
-    .toBe(true);
-  await setScale(page, SCALE);
-  await expect
-    .poll(async () => ((await getState(page)).planes.every((p) => p.status === 'available')), {
-      timeout: 240_000,
-      message: 'waiting for both planes to land',
-    })
-    .toBe(true);
-
-  const pre = await getState(page);
-  const starter = pre.planes.find((p) => p.id === STARTER)!;
-  const second = pre.planes.find((p) => p.id === secondId)!;
-  expect(starter.fuel, 'the hop burned fuel').toBeLessThan(starter.maxFuel);
-  expect(second.fuel, 'the hop burned fuel').toBeLessThan(second.maxFuel);
-
-  // The left-pane Refuel section lists BOTH grounded planes with partial tanks…
-  const refuelSelect = page.getByTestId('market-refuel-plane');
-  await expect(refuelSelect).toBeVisible({ timeout: 15_000 });
-  await expect(refuelSelect.locator(`option[value="${STARTER}"]`)).toHaveCount(1);
-  await expect(refuelSelect.locator(`option[value="${secondId}"]`)).toHaveCount(1);
-
-  // …select the SECOND plane — the preview is its exact fill-up cost (mirrors refuelPlane 'full'),
-  // rep-scaled (v0.38.0, ISS-072) from the live snapshot's reputation.
-  const fuelRate = repRate(pre.account.reputation, FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT);
-  const expectedCost = Math.round((second.maxFuel - second.fuel) * pre.fuelPricePerL * (1 - fuelRate) * 100) / 100;
-  await refuelSelect.selectOption(secondId);
-  await expect(page.getByTestId('market-refuel-cost')).toContainText(eur(expectedCost));
-
-  await page.getByTestId('market-refuel').click();
-  await expect
-    .poll(async () => {
-      const s = await getState(page);
-      return Math.abs(s.account.cash - (pre.account.cash - expectedCost)) < 0.001;
-    }, { timeout: 15_000, message: 'waiting for the refuel cost to land in /api/state' })
-    .toBe(true);
-
-  const post = await getState(page);
-  expect(post.planes.find((p) => p.id === secondId)!.fuel, 'that tank is full').toBe(second.maxFuel);
-  expect(post.planes.find((p) => p.id === STARTER)!.fuel, 'the other tank is untouched').toBe(starter.fuel);
-});
 
 test('relocate section moves one plane without touching the other', async ({ page }) => {
   test.setTimeout(300_000); // self-heal + one short hop at scale 1000
@@ -524,7 +474,7 @@ test('per-plane queues are independent; landing auto-chains the next queued leg'
   const [a, b] = await twoNearestToHub(page);
 
   // Full tank for the starter — it flies both legs (EDDF→a then the auto-chained a→b).
-  expect((await page.request.post(`/api/planes/${STARTER}/refuel`)).status()).toBe(200);
+  await setFuelFull(page, STARTER);
 
   // Seed one queued leg per plane via the API so BOTH on-board blocks render…
   expect((await page.request.post(`/api/planes/${STARTER}/queue`, { data: { destIcao: a.icao } })).status()).toBe(200);

lib/db/client.ts

@@ -31,7 +31,9 @@ CREATE TABLE IF NOT EXISTS planes (
   lat REAL NOT NULL,
   lon REAL NOT NULL,
   departure_sim_time INTEGER,
-  queue TEXT NOT NULL DEFAULT '[]'
+  queue TEXT NOT NULL DEFAULT '[]',
+  health REAL NOT NULL DEFAULT 100,
+  repair_until_sim_time INTEGER
 );
 CREATE TABLE IF NOT EXISTS packages (
   id TEXT PRIMARY KEY NOT NULL,
@@ -88,6 +90,14 @@ function migrateColumns(raw: RawSqlJsDatabase): void {
   if (!cols('packages').has('special')) {
     raw.exec('ALTER TABLE packages ADD COLUMN special TEXT');
   }
+  // v0.39.0 (ISS-069): plane health — pre-existing rows backfill to full health.
+  if (!cols('planes').has('health')) {
+    raw.exec('ALTER TABLE planes ADD COLUMN health REAL NOT NULL DEFAULT 100');
+  }
+  // v0.39.0 (ISS-069): repair gate — nullable, no default; pre-existing rows stay NULL = not in repair.
+  if (!cols('planes').has('repair_until_sim_time')) {
+    raw.exec('ALTER TABLE planes ADD COLUMN repair_until_sim_time INTEGER');
+  }
   // v0.30.0 (ISS-057): last-selected speed — pre-existing rows backfill to the row's OWN
   // current time_scale so a legacy DB resumes at the speed it was running, not the default.
   if (!cols('sim_state').has('last_selected_time_scale')) {

lib/db/schema.ts

@@ -7,7 +7,9 @@ import { integer, real, sqliteTable, text } from 'drizzle-orm/sqlite-core';
 export const planes = sqliteTable('planes', {
   id: text('id').primaryKey().notNull(),
   model: text('model').notNull(),
-  status: text('status', { enum: ['available', 'flying'] }).notNull(),
+  // v0.39.0 (ISS-069): 'repairing' = grounded in the shop until repairUntilSimTime passes; the
+  // engine flips it back to 'available' on a tick. All status guards key off 'available'.
+  status: text('status', { enum: ['available', 'flying', 'repairing'] }).notNull(),
   fuel: real('fuel').notNull(),
   maxFuel: real('max_fuel').notNull(),
   locationIcao: text('location_icao').notNull(),
@@ -24,6 +26,12 @@ export const planes = sqliteTable('planes', {
   // of ICAO strings ('[]' when empty). The ACTIVE leg stays destIcao +
   // departureSimTime; on landing the engine auto-chains queue[0] if fuel covers it.
   queue: text('queue').notNull().default('[]'),
+  // Structural health in [0, 100] (v0.39.0, ISS-069) — wears down by WEAR_PER_KM per km of
+  // landed legs; at 0 the plane is broken and burns BROKEN_BURN_MULTIPLIER × more fuel.
+  health: real('health').notNull().default(100),
+  // Sim-clock epoch ms when an active repair finishes (v0.39.0, ISS-069) — set with status
+  // 'repairing', cleared by the engine's flip-back pass; NULL = not in repair.
+  repairUntilSimTime: integer('repair_until_sim_time'),
 });
 
 // Cargo packages (v0.12.0) replace the old contracts table end-to-end: a package

lib/deriveEvents.test.ts

@@ -22,6 +22,8 @@ const basePlane = (id: string): PlaneState => ({
   departureSimTime: null,
   lat: 50.03,
   lon: 8.56,
+  health: 100, // v0.39.0 (ISS-069) — full-health fixture default
+  repairUntilSimTime: null,
   queue: [],
 });
 

lib/game/actions.test.ts

@@ -10,12 +10,15 @@ import { haversineKm, initialBearingDeg } from '@/lib/geo';
 import { weatherFor } from '@/lib/weather';
 import { requiredFuelFor, windBurnFactor } from '@/lib/sim/movement';
 import {
+  BROKEN_BURN_MULTIPLIER,
   FUEL_DISCOUNT_PER_REP,
   FUEL_PRICE_PER_L,
   MAX_FUEL_DISCOUNT,
   MAX_PLANE_DISCOUNT,
   PLANE_DISCOUNT_PER_REP,
   PLANE_TYPES,
+  REPAIR_COST,
+  REPAIR_DURATION_MS,
   repRate,
   SELL_FRACTION,
 } from './catalog';
@@ -29,7 +32,7 @@ import {
   ignorePackage,
   loadPackage,
   queueLeg,
-  refuelPlane,
+  repairPlane,
   sellPlane,
 } from './actions';
 
@@ -227,11 +230,115 @@ describe('flyPlane', () => {
     await expectActionError(flyPlane(inst, 'plane-starter', 'ZZZZ'), 400, /unknown airport/);
   });
 
-  it('rejects a leg the plane cannot fuel with 409 (burn > fuel)', async () => {
+  it('uses the ×1.5 broken burn for the dispatch auto-top-up when health is 0 (v0.39.0, ISS-069)', async () => {
-    const inst = await freshDb('fly-nofuel.db'); // EDDF → LEMD ≈ 1950 km × 1.75 L/km ≈ 3400 L
+    const inst = await freshDb('fly-broken.db'); // EDDF → LEMD
-    await inst.db.update(schema.planes).set({ fuel: 1 }).where(eq(schema.planes.id, 'plane-starter'));
+    const fc = await loadAirportsGeoJson();
+    const from = fc.features.find((f) => f.properties.icao === HUB_ICAO)!.properties;
+    const to = fc.features.find((f) => f.properties.icao === 'LEMD')!.properties;
+    const km = haversineKm(from.lat, from.lon, to.lat, to.lon);
+    const type = PLANE_TYPES.atr72;
+    const w = weatherFor(HUB_ICAO);
+    const f = windBurnFactor(w.windKt, w.windDirDeg, initialBearingDeg(from.lat, from.lon, to.lat, to.lon));
+    // The tank holds EXACTLY the healthy requirement — a broken plane's 150% top-up target is higher.
+    const healthyRequired = requiredFuelFor(type.burnPerKm * f, type.emptyWeightKg, type.maxFuel, km);
+    await inst.db.update(schema.planes)
+      .set({ health: 0, fuel: healthyRequired })
+      .where(eq(schema.planes.id, 'plane-starter'));
 
-    await expectActionError(flyPlane(inst, 'plane-starter', 'LEMD'), 409, /insufficient fuel/i);
+    await flyPlane(inst, 'plane-starter', 'LEMD'); // auto-refuel covers the extra burn — no 409
+
+    const brokenRequired = requiredFuelFor(type.burnPerKm * f * BROKEN_BURN_MULTIPLIER, type.emptyWeightKg, type.maxFuel, km);
+    expect(brokenRequired).toBeGreaterThan(healthyRequired); // sanity: the multiplier genuinely raises the requirement
+    const plane = (await inst.db.select().from(schema.planes))[0];
+    expect(plane.status).toBe('flying');
+    expect(plane.fuel).toBeCloseTo(Math.min(type.maxFuel, Math.max(healthyRequired, brokenRequired * 1.5)), 6); // topped up for the BROKEN burn…
+
+    // …while the same tank at full health tops up to the LOWER healthy target — the multiplier is what raised it.
+    const inst2 = await freshDb('fly-broken-healthy.db');
+    await inst2.db.update(schema.planes).set({ fuel: healthyRequired }).where(eq(schema.planes.id, 'plane-starter'));
+    await flyPlane(inst2, 'plane-starter', 'LEMD'); // must not throw
+    const plane2 = (await inst2.db.select().from(schema.planes))[0];
+    expect(plane2.fuel).toBeCloseTo(Math.min(type.maxFuel, Math.max(healthyRequired, healthyRequired * 1.5)), 6);
+    expect(plane.fuel).toBeGreaterThan(plane2.fuel); // the broken plane genuinely got more fuel
+  });
+
+  // --- Auto-refuel on dispatch (ISS-082, v0.42.0) ---
+
+  // Wind-adjusted requirement for the hub → LEMD leg — computed with the SAME helpers flyPlane uses,
+  // so the expectations stay exact without hardcoded literals.
+  async function adjustedRequiredForHubToLemd() {
+    const fc = await loadAirportsGeoJson();
+    const from = fc.features.find((f) => f.properties.icao === HUB_ICAO)!.properties;
+    const to = fc.features.find((f) => f.properties.icao === 'LEMD')!.properties;
+    const km = haversineKm(from.lat, from.lon, to.lat, to.lon);
+    const type = PLANE_TYPES.atr72;
+    const w = weatherFor(HUB_ICAO);
+    return requiredFuelFor(
+      type.burnPerKm * windBurnFactor(w.windKt, w.windDirDeg, initialBearingDeg(from.lat, from.lon, to.lat, to.lon)),
+      type.emptyWeightKg,
+      type.maxFuel,
+      km,
+    );
+  }
+
+  it('auto-refuels on dispatch: tops up to min(maxFuel, max(fuel, 1.5 × required)) and deducts the rep-discounted cost', async () => {
+    const inst = await freshDb('fly-autorefuel.db'); // EDDF → LEMD
+    const required = await adjustedRequiredForHubToLemd();
+    const startFuel = Math.round(required / 2); // partial tank below the requirement
+    await inst.db.update(schema.planes).set({ fuel: startFuel }).where(eq(schema.planes.id, 'plane-starter'));
+    // Elevated rep → non-zero discount rate; expectations computed with the SAME helpers flyPlane uses.
+    await inst.db.update(schema.account).set({ reputation: 30 });
+    const cashBefore = (await inst.db.select().from(schema.account))[0].cash;
+
+    await flyPlane(inst, 'plane-starter', 'LEMD');
+
+    const rate = repRate(30, FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT);
+    expect(rate).toBeGreaterThan(0); // sanity pin on the formula input
+    const target = Math.min(PLANE_TYPES.atr72.maxFuel, Math.max(startFuel, required * 1.5));
+    const expectedCost = Math.round((target - startFuel) * FUEL_PRICE_PER_L * (1 - rate) * 100) / 100;
+    expect(expectedCost).toBeGreaterThan(0); // the top-up genuinely costs something
+
+    const plane = (await inst.db.select().from(schema.planes))[0];
+    expect(plane.status).toBe('flying');
+    expect(plane.fuel).toBeCloseTo(target, 6); // topped up to exactly the 150% target…
+    const account = (await inst.db.select().from(schema.account))[0];
+    expect(account.cash).toBeCloseTo(cashBefore - expectedCost, 6); // …at exactly the rep-discounted cost
+  });
+
+  it('is a free no-op when the tank already covers the 150% target (cash unchanged)', async () => {
+    const inst = await freshDb('fly-autorefuel-full.db'); // seeded starter is full at EDDF
+    const required = await adjustedRequiredForHubToLemd();
+    expect(required * 1.5).toBeLessThan(PLANE_TYPES.atr72.maxFuel); // sanity: the target stays below a full tank
+    const cashBefore = (await inst.db.select().from(schema.account))[0].cash;
+
+    await flyPlane(inst, 'plane-starter', 'LEMD');
+
+    const plane = (await inst.db.select().from(schema.planes))[0];
+    expect(plane.status).toBe('flying');
+    expect(plane.fuel).toBe(PLANE_TYPES.atr72.maxFuel); // untouched…
+    expect((await inst.db.select().from(schema.account))[0].cash).toBe(cashBefore); // …and free
+  });
+
+  it('rejects dispatch with 409 insufficient funds when cash cannot cover the top-up — nothing mutated', async () => {
+    const inst = await freshDb('fly-autorefuel-poor.db'); // EDDF → LEMD
+    const required = await adjustedRequiredForHubToLemd();
+    const startFuel = Math.round(required / 2);
+    await inst.db.update(schema.planes).set({ fuel: startFuel }).where(eq(schema.planes.id, 'plane-starter'));
+    await inst.db.update(schema.account).set({ cash: 0 });
+
+    await expectActionError(flyPlane(inst, 'plane-starter', 'LEMD'), 409, /insufficient funds/i);
+
+    const plane = (await inst.db.select().from(schema.planes))[0];
+    expect(plane.status).toBe('available'); // still grounded…
+    expect(plane.fuel).toBe(startFuel); // …with the fuel UNCHANGED — nothing was mutated
+  });
+
+  it('still rejects a leg that does not fit even a full tank with 409 (the auto-refuel backstop)', async () => {
+    const inst = await freshDb('fly-autorefuel-nofit.db');
+    // UNNT ↔ LPPD are ~7670 km apart — far beyond the ATR's range, so no top-up can make it flyable.
+    await inst.db.update(schema.planes).set({ locationIcao: 'UNNT' }).where(eq(schema.planes.id, 'plane-starter'));
+
+    await expectActionError(flyPlane(inst, 'plane-starter', 'LPPD'), 409, /insufficient fuel/i);
   });
 });
 
@@ -584,198 +691,81 @@ describe('sellPlane', () => {
   });
 });
 
-describe('refuelPlane', () => {
+describe('repairPlane (v0.39.0, ISS-069)', () => {
-  it('fills to maxFuel and deducts (maxFuel − fuel) × FUEL_PRICE_PER_L from cash', async () => {
+  it('charges exactly REPAIR_COST, restores health to 100 and grounds the plane for REPAIR_DURATION_MS', async () => {
-    const inst = await freshDb('refuel-ok.db');
+    const inst = await freshDb('repair-ok.db');
-    await inst.db.update(schema.planes).set({ fuel: 1_000 }).where(eq(schema.planes.id, 'plane-starter'));
+    await inst.db.update(schema.planes).set({ health: 42 }).where(eq(schema.planes.id, 'plane-starter'));
     const cashBefore = (await inst.db.select().from(schema.account))[0].cash;
 
-    const { cost } = await refuelPlane(inst, 'plane-starter');
+    const { cost } = await repairPlane(inst, 'plane-starter');
 
-    expect(cost).toBe(Math.round((PLANE_TYPES.atr72.maxFuel - 1_000) * FUEL_PRICE_PER_L * 100) / 100);
+    expect(cost).toBe(REPAIR_COST);
     const plane = (await inst.db.select().from(schema.planes))[0];
-    expect(plane.fuel).toBe(PLANE_TYPES.atr72.maxFuel);
+    expect(plane.status).toBe('repairing');
+    expect(plane.health).toBe(100); // restored to full…
+    expect(plane.repairUntilSimTime).toBe(T0 + REPAIR_DURATION_MS); // …with the gate set from the seeded clock (no tick in direct calls)
     const account = (await inst.db.select().from(schema.account))[0];
-    expect(account.cash).toBeCloseTo(cashBefore - cost, 6);
+    expect(account.cash).toBeCloseTo(cashBefore - REPAIR_COST, 6);
   });
 
-  it('is a free no-op when the tank is already full', async () => {
+  it('is a free no-op when health is already full', async () => {
-    const inst = await freshDb('refuel-full.db'); // seeded starter is full
+    const inst = await freshDb('repair-full.db'); // seeded starter at 100
     const cashBefore = (await inst.db.select().from(schema.account))[0].cash;
 
-    const { cost } = await refuelPlane(inst, 'plane-starter');
+    const { cost } = await repairPlane(inst, 'plane-starter');
 
     expect(cost).toBe(0);
+    const plane = (await inst.db.select().from(schema.planes))[0];
+    expect(plane.status).toBe('available'); // not grounded…
+    expect(plane.health).toBe(100);
+    expect(plane.repairUntilSimTime ?? null).toBeNull(); // …and no gate set
     expect((await inst.db.select().from(schema.account))[0].cash).toBe(cashBefore);
   });
 
   it('rejects a flying plane with 409', async () => {
-    const inst = await freshDb('refuel-flying.db');
+    const inst = await freshDb('repair-flying.db');
     await inst.db.update(schema.planes)
       .set({ status: 'flying', departureSimTime: T0, destIcao: 'LEMD' })
       .where(eq(schema.planes.id, 'plane-starter'));
 
-    await expectActionError(refuelPlane(inst, 'plane-starter'), 409, /flying/);
+    await expectActionError(repairPlane(inst, 'plane-starter'), 409, /only grounded planes can be repaired/);
   });
 
-  it('rejects the fill-up when cash is below the cost with 409', async () => {
+  it('rejects a plane that is already repairing with 409', async () => {
-    const inst = await freshDb('refuel-poor.db');
+    const inst = await freshDb('repair-busy.db');
-    await inst.db.update(schema.planes).set({ fuel: 1_000 }).where(eq(schema.planes.id, 'plane-starter'));
+    await inst.db.update(schema.planes)
-    await inst.db.update(schema.account).set({ cash: 10 }); // cost is ~4960
+      .set({ status: 'repairing', repairUntilSimTime: T0 + REPAIR_DURATION_MS })
+      .where(eq(schema.planes.id, 'plane-starter'));
 
-    await expectActionError(refuelPlane(inst, 'plane-starter'), 409, /insufficient funds/i);
+    await expectActionError(repairPlane(inst, 'plane-starter'), 409, /only grounded planes can be repaired/);
   });
 
-  it('applies the reputation-scaled discount to the price term only, in both modes (v0.38.0)', async () => {
+  it('blocks load/fly/sell while repairing (the existing status guards)', async () => {
-    const inst = await freshDb('refuel-rep.db');
+    const inst = await freshDb('repair-blocks.db');
-    // Elevated rep → non-zero rate; expectations computed with the SAME helpers refuelPlane uses.
+    await inst.db.update(schema.planes).set({ health: 50 }).where(eq(schema.planes.id, 'plane-starter'));
-    await inst.db.update(schema.account).set({ reputation: 30 });
+    await repairPlane(inst, 'plane-starter');
-    const rate = repRate(30, FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT);
-    expect(rate).toBeGreaterThan(0);
 
-    // 'full': exact discounted cost, tank math untouched.
+    await insertOpenPackage(inst); // open package at the hub — loadable if the plane were grounded
-    await inst.db.update(schema.planes).set({ fuel: 1_000 }).where(eq(schema.planes.id, 'plane-starter'));
+    await expectActionError(loadPackage(inst, 'p-open', 'plane-starter'), 409, /repairing/);
-    const cashBefore = (await inst.db.select().from(schema.account))[0].cash;
+    await expectActionError(flyPlane(inst, 'plane-starter', 'LEMD'), 409, /repairing/);
-    const { cost } = await refuelPlane(inst, 'plane-starter');
+    // A second plane so the "last remaining" guard cannot fire before the status one.
-    expect(cost).toBe(Math.round((PLANE_TYPES.atr72.maxFuel - 1_000) * FUEL_PRICE_PER_L * (1 - rate) * 100) / 100);
+    await inst.db.insert(schema.planes).values({
-    const plane = (await inst.db.select().from(schema.planes))[0];
+      id: 'plane-extra', model: 'atr72', status: 'available', fuel: 100, maxFuel: PLANE_TYPES.atr72.maxFuel,
-    expect(plane.fuel).toBe(PLANE_TYPES.atr72.maxFuel); // target unchanged by the discount
+      locationIcao: HUB_ICAO, destIcao: null, lat: 50, lon: 8, departureSimTime: null,
-    expect((await inst.db.select().from(schema.account))[0].cash).toBeCloseTo(cashBefore - cost, 6);
+    });
+    await expectActionError(sellPlane(inst, 'plane-starter'), 409, /repairing/);
+  });
 
-    // 'forFlight': same discount on the price term; burn/target math (wind factor, ×1.5 margin) untouched.
+  it('rejects the repair when cash is below REPAIR_COST with 409', async () => {
-    await insertOpenPackage(inst, 'p-ff-r', { destIcao: 'LEMD' }); // EDDF → LEMD
+    const inst = await freshDb('repair-poor.db');
-    await loadPackage(inst, 'p-ff-r', 'plane-starter');
+    await inst.db.update(schema.planes).set({ health: 50 }).where(eq(schema.planes.id, 'plane-starter'));
-    const required = await adjustedRequiredForHubToLemd();
+    await inst.db.update(schema.account).set({ cash: REPAIR_COST - 1 });
-    const startFuel = Math.round(required / 2);
-    await inst.db.update(schema.planes).set({ fuel: startFuel }).where(eq(schema.planes.id, 'plane-starter'));
-    const cashBefore2 = (await inst.db.select().from(schema.account))[0].cash;
 
-    const { cost: ffCost } = await refuelPlane(inst, 'plane-starter', { mode: 'forFlight', packageId: 'p-ff-r' });
+    await expectActionError(repairPlane(inst, 'plane-starter'), 409, /insufficient funds/i);
-
-    const targetFuel = Math.min(PLANE_TYPES.atr72.maxFuel, Math.max(startFuel, required * 1.5));
-    expect(ffCost).toBe(Math.round((targetFuel - startFuel) * FUEL_PRICE_PER_L * (1 - rate) * 100) / 100);
-    const plane2 = (await inst.db.select().from(schema.planes))[0];
-    expect(plane2.fuel).toBeCloseTo(targetFuel, 6); // topped up to exactly the 150% target
-    expect((await inst.db.select().from(schema.account))[0].cash).toBeCloseTo(cashBefore2 - ffCost, 6);
   });
 
   it('rejects an unknown id with 404', async () => {
-    const inst = await freshDb('refuel-unknown.db');
+    const inst = await freshDb('repair-unknown.db');
-    await expectActionError(refuelPlane(inst, 'ghost'), 404);
+    await expectActionError(repairPlane(inst, 'ghost'), 404);
-  });
-
-  // --- forFlight mode (v0.16.0) ---
-
-  // Wind-adjusted requirement for the hub → LEMD leg (v0.36.0) — computed with the SAME helpers
-  // refuelPlane uses, so the expectations stay exact without hardcoded literals.
-  async function adjustedRequiredForHubToLemd() {
-    const fc = await loadAirportsGeoJson();
-    const from = fc.features.find((f) => f.properties.icao === HUB_ICAO)!.properties;
-    const to = fc.features.find((f) => f.properties.icao === 'LEMD')!.properties;
-    const km = haversineKm(from.lat, from.lon, to.lat, to.lon);
-    const type = PLANE_TYPES.atr72;
-    const w = weatherFor(HUB_ICAO);
-    return requiredFuelFor(
-      type.burnPerKm * windBurnFactor(w.windKt, w.windDirDeg, initialBearingDeg(from.lat, from.lon, to.lat, to.lon)),
-      type.emptyWeightKg,
-      type.maxFuel,
-      km,
-    );
-  }
-
-  it('forFlight buys 150% of the weather-adjusted leg requirement and deducts L × price', async () => {
-    const inst = await freshDb('refuel-forflight-ok.db');
-    await insertOpenPackage(inst, 'p-ff', { destIcao: 'LEMD' }); // EDDF → LEMD
-    await loadPackage(inst, 'p-ff', 'plane-starter');
-
-    const required = await adjustedRequiredForHubToLemd();
-
-    // Partial tank below the requirement so L > 0.
-    const startFuel = Math.round(required / 2);
-    await inst.db.update(schema.planes).set({ fuel: startFuel }).where(eq(schema.planes.id, 'plane-starter'));
-    const cashBefore = (await inst.db.select().from(schema.account))[0].cash;
-
-    const { cost } = await refuelPlane(inst, 'plane-starter', { mode: 'forFlight', packageId: 'p-ff' });
-
-    // ISS-071: target is 150% of the requirement (below tank capacity for this leg).
-    const targetFuel = Math.min(PLANE_TYPES.atr72.maxFuel, Math.max(startFuel, required * 1.5));
-    expect(cost).toBe(Math.round((targetFuel - startFuel) * FUEL_PRICE_PER_L * 100) / 100);
-    const plane = (await inst.db.select().from(schema.planes))[0];
-    expect(plane.fuel).toBeCloseTo(targetFuel, 6); // topped up to exactly the 150% target
-    const account = (await inst.db.select().from(schema.account))[0];
-    expect(account.cash).toBeCloseTo(cashBefore - cost, 6);
-  });
-
-  it('forFlight leaves a tank with a 50% margin — flyPlane to the package dest succeeds right after', async () => {
-    const inst = await freshDb('refuel-ff-flyafter.db');
-    await insertOpenPackage(inst, 'p-fa', { destIcao: 'LEMD' }); // EDDF → LEMD
-    await loadPackage(inst, 'p-fa', 'plane-starter');
-
-    const required = await adjustedRequiredForHubToLemd();
-
-    // Empty-ish tank: well below the leg requirement.
-    await inst.db.update(schema.planes).set({ fuel: Math.round(required / 4) }).where(eq(schema.planes.id, 'plane-starter'));
-
-    await refuelPlane(inst, 'plane-starter', { mode: 'forFlight', packageId: 'p-fa' });
-
-    // The leg must now be flyable — the 150% margin covers flyPlane's strict `>` check.
-    await flyPlane(inst, 'plane-starter', 'LEMD');
-    const plane = (await inst.db.select().from(schema.planes))[0];
-    expect(plane.status).toBe('flying');
-    expect(plane.destIcao).toBe('LEMD');
-  });
-
-  it('forFlight is a free no-op when the tank already covers the leg', async () => {
-    const inst = await freshDb('refuel-forflight-enough.db'); // seeded starter is full at EDDF
-    await insertOpenPackage(inst, 'p-ff2', { destIcao: 'LEMD' });
-    await loadPackage(inst, 'p-ff2', 'plane-starter');
-    const cashBefore = (await inst.db.select().from(schema.account))[0].cash;
-
-    const { cost } = await refuelPlane(inst, 'plane-starter', { mode: 'forFlight', packageId: 'p-ff2' });
-
-    expect(cost).toBe(0);
-    const plane = (await inst.db.select().from(schema.planes))[0];
-    expect(plane.fuel).toBe(PLANE_TYPES.atr72.maxFuel); // untouched
-    expect((await inst.db.select().from(schema.account))[0].cash).toBe(cashBefore);
-  });
-
-  it('forFlight rejects a package that is not loaded on this plane with 409', async () => {
-    const inst = await freshDb('refuel-ff-open.db'); // open — never loaded
-    await insertOpenPackage(inst, 'p-x');
-    await expectActionError(refuelPlane(inst, 'plane-starter', { mode: 'forFlight', packageId: 'p-x' }), 409);
-
-    const inst2 = await freshDb('refuel-ff-other.db'); // loaded on ANOTHER plane
-    await insertOpenPackage(inst2, 'p-y', { status: 'loaded', planeId: 'plane-someone-else' });
-    await expectActionError(refuelPlane(inst2, 'plane-starter', { mode: 'forFlight', packageId: 'p-y' }), 409);
-  });
-
-  it('forFlight rejects an expired package with 409', async () => {
-    const inst = await freshDb('refuel-ff-expired.db');
-    await insertOpenPackage(inst, 'p-z', { status: 'expired', planeId: 'plane-starter' });
-    await expectActionError(refuelPlane(inst, 'plane-starter', { mode: 'forFlight', packageId: 'p-z' }), 409);
-  });
-
-  it('forFlight rejects an unknown package id with 404', async () => {
-    const inst = await freshDb('refuel-ff-unknown.db');
-    await expectActionError(refuelPlane(inst, 'plane-starter', { mode: 'forFlight', packageId: 'nope' }), 404);
-  });
-
-  it('forFlight rejects a missing packageId with 400', async () => {
-    const inst = await freshDb('refuel-ff-nopkg.db');
-    await expectActionError(refuelPlane(inst, 'plane-starter', { mode: 'forFlight' }), 400);
-  });
-
-  it('forFlight rejects a leg that does not fit even a full tank with 409', async () => {
-    const inst = await freshDb('refuel-ff-nofit.db');
-    // UNNT (Narsarsuaq, Greenland) ↔ LPPD are ~7670 km apart — far beyond the ATR's range.
-    await insertOpenPackage(inst, 'p-far', { destIcao: 'LPPD' });
-    await loadPackage(inst, 'p-far', 'plane-starter');
-    await inst.db.update(schema.planes).set({ locationIcao: 'UNNT' }).where(eq(schema.planes.id, 'plane-starter'));
-
-    await expectActionError(
-      refuelPlane(inst, 'plane-starter', { mode: 'forFlight', packageId: 'p-far' }),
-      409,
-      /does not fit/i,
-    );
   });
 });

lib/game/actions.ts

@@ -9,12 +9,15 @@ import { requiredFuelFor, windBurnFactor } from '@/lib/sim/movement';
 import { runAction } from '@/lib/sim/engine';
 import { getStateSnapshot, parseIcaoQueue } from './state';
 import {
+  conditionBurnMultiplier,
   FUEL_DISCOUNT_PER_REP,
   FUEL_PRICE_PER_L,
   MAX_FUEL_DISCOUNT,
   MAX_PLANE_DISCOUNT,
   PLANE_DISCOUNT_PER_REP,
   PLANE_TYPES,
+  REPAIR_COST,
+  REPAIR_DURATION_MS,
   repRate,
   SELL_FRACTION,
 } from './catalog';
@@ -22,9 +25,9 @@ import { abandonPenalty } from './penalty';
 import { HUB_ICAO } from './seed';
 
 // Player actions (v0.8.0, package model v0.12.0) — the core loop, server-side:
-// load a package onto a grounded plane at its origin, fly to any airport, deliver
+// load a package onto a grounded plane at its origin, fly to any airport (dispatch
-// on arrival, abandon for a penalty while grounded; plus buy/sell planes and
+// auto-refuels first — ISS-082), deliver on arrival, abandon for a penalty while
-// refuel. Each function validates and mutates ONE throwaway-safe GameDb instance
+// grounded; plus buy/sell planes. Each function validates and mutates ONE throwaway-safe GameDb instance
 // (persisted at the end); routes wrap them in engine.runAction() so tick +
 // validate + mutate are atomic under the sim lock. Validation failures throw
 // GameActionError carrying the HTTP status:
@@ -99,7 +102,11 @@ export async function loadPackage(inst: GameDb, packageId: string, planeId: stri
 // Manual flight (v0.12.0): a grounded plane can fly to ANY known airport — its
 // loaded packages' destinations or pure repositioning. On arrival the engine
 // delivers whatever is bound for that airport. Validation: plane 'available',
-// destination in the airport dataset, enough fuel for the leg.
+// destination in the airport dataset, enough fuel for the leg. ISS-082 (v0.42.0):
+// dispatch AUTO-refuels first — the tank is topped up to min(maxFuel, max(fuel, 1.5 × required))
+// at FUEL_PRICE_PER_L per liter minus the rep-scaled discount, deducted from cash; a leg that
+// doesn't fit even a full tank still 409s (insufficient fuel), and an unaffordable top-up 409s
+// with nothing mutated.
 export async function flyPlane(inst: GameDb, planeId: string, destIcao: string): Promise<void> {
   const planeRows = await inst.db.select().from(schema.planes).where(eq(schema.planes.id, planeId));
   const plane = planeRows[0];
@@ -118,11 +125,26 @@ export async function flyPlane(inst: GameDb, planeId: string, destIcao: string):
   const distanceKm = haversineKm(origin.lat, origin.lon, destFeature.properties.lat, destFeature.properties.lon);
   // Weighted burn model (v0.16.0): the leg needs enough fuel to cover it arriving empty; wind-
   // adjusted (v0.36.0) by departure weather vs route heading — every call site uses this same factor.
+  // v0.39.0 (ISS-069): a broken plane (health ≤ 0) burns BROKEN_BURN_MULTIPLIER × more per km.
   const w = weatherFor(plane.locationIcao);
-  const burnPerKm = type.burnPerKm * windBurnFactor(w.windKt, w.windDirDeg, initialBearingDeg(origin.lat, origin.lon, destFeature.properties.lat, destFeature.properties.lon));
+  const burnPerKm = type.burnPerKm * windBurnFactor(w.windKt, w.windDirDeg, initialBearingDeg(origin.lat, origin.lon, destFeature.properties.lat, destFeature.properties.lon)) * conditionBurnMultiplier(plane.health);
   const requiredL = requiredFuelFor(burnPerKm, type.emptyWeightKg, type.maxFuel, distanceKm);
-  if (requiredL > plane.fuel) {
+
-    throw new GameActionError(409, `insufficient fuel: the leg needs ${Math.round(requiredL)} L but the plane has ${Math.round(plane.fuel)} L`);
+  // ISS-082 (v0.42.0): dispatch auto-refuels — top up to 150% of the requirement (capped at tank
+  // capacity) so burn variance doesn't strand the plane; cost = liters × FUEL_PRICE_PER_L minus
+  // the rep-scaled discount (same price term as the removed manual refuel). All checks run BEFORE
+  // any mutation, so a 409 leaves fuel and cash untouched.
+  const target = Math.min(plane.maxFuel, Math.max(plane.fuel, requiredL * 1.5));
+  const liters = Math.max(0, target - plane.fuel);
+  const account = (await inst.db.select().from(schema.account))[0];
+  if (!account) throw new Error('account row missing');
+  const cost = Math.round(liters * FUEL_PRICE_PER_L * (1 - repRate(account.reputation, FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT)) * 100) / 100;
+  if (cost > 0 && account.cash < cost) {
+    throw new GameActionError(409, `insufficient funds: refueling costs ${cost}, you have ${Math.round(account.cash)}`);
+  }
+  // Backstop: a leg that doesn't fit even a full tank is unflyable (target caps at maxFuel).
+  if (requiredL > target) {
+    throw new GameActionError(409, `insufficient fuel: the leg needs ${Math.round(requiredL)} L but the plane has ${Math.round(target)} L`);
   }
 
   // runAction() ticked first, so this is current game time.
@@ -136,8 +158,12 @@ export async function flyPlane(inst: GameDb, planeId: string, destIcao: string):
       departureSimTime: sim.clockMs,
       lat: origin.lat,
       lon: origin.lon,
+      fuel: target, // ISS-082: the post-top-up level (unchanged when no top-up was needed)
     })
     .where(eq(schema.planes.id, planeId));
+  if (cost > 0) {
+    await inst.db.update(schema.account).set({ cash: Math.round((account.cash - cost) * 100) / 100 });
+  }
   // ISS-057: dispatch still resumes a MANUALLY paused sim (pause is manual-only now — landings
   // slow to 1× instead of pausing), and restores the last manually selected speed when this
   // dispatch took the LAST grounded plane airborne. Runs inside runAction(), so tick + controls
@@ -284,6 +310,7 @@ export async function buyPlane(inst: GameDb, model: string): Promise<{ planeId:
     lat: home.lat,
     lon: home.lon,
     departureSimTime: null,
+    health: 100, // new planes arrive at full health (v0.39.0, ISS-069)
   });
   await inst.db.update(schema.account).set({ cash: Math.round((account.cash - cost) * 100) / 100 });
   await persist(inst);
@@ -326,82 +353,36 @@ export async function sellPlane(inst: GameDb, planeId: string): Promise<{ payout
   return { payout };
 }
 
-// --- Refuel (POST /api/planes/:planeId/refuel) ---
+// --- Repair (POST /api/planes/:planeId/repair) — v0.39.0 (ISS-069) ---
 
-// Refuel modes (v0.16.0): 'full' fills the tank to maxFuel; 'forFlight' buys 150% of
+// Restore a worn-out plane to full health for the flat REPAIR_COST; it is grounded in 'repairing'
-// the fuel required for one loaded package's destination leg (ISS-071) — wind-adjusted
+// status until sim.clockMs + REPAIR_DURATION_MS, when the engine's tick flips it back to
-// requirement per the weighted burn model, capped at tank capacity, independent of how
+// 'available'. Only GROUNDED planes can be repaired (409 otherwise); an already-full-health
-// much is already in the tank.
+// repair is a free no-op. 404 unknown plane; 409 not grounded / insufficient funds.
-export interface RefuelOptions {
+export async function repairPlane(inst: GameDb, planeId: string): Promise<{ cost: number }> {
-  mode?: 'full' | 'forFlight';
-  packageId?: string;
-}
-
-// Fill a grounded plane to maxFuel at FUEL_PRICE_PER_L per missing liter — or, with
-// {mode:'forFlight', packageId}, top it up just enough to fly the loaded package's
-// destination leg (409 if the package isn't loaded on this plane, is expired, or the
-// leg doesn't fit a full tank).
-export async function refuelPlane(inst: GameDb, planeId: string, opts: RefuelOptions = {}): Promise<{ cost: number }> {
   const rows = await inst.db.select().from(schema.planes).where(eq(schema.planes.id, planeId));
   const plane = rows[0];
   if (!plane) throw new GameActionError(404, `plane ${planeId} not found`);
   if (plane.status !== 'available') {
-    throw new GameActionError(409, `plane is ${plane.status}, only grounded planes can be refueled`);
+    throw new GameActionError(409, `plane is ${plane.status}, only grounded planes can be repaired`);
   }
+  // Free no-op when the plane is already at full health — nothing to repair.
+  if (plane.health >= 100) return { cost: 0 };
 
-  const mode = opts.mode ?? 'full';
+  const sim = (await inst.db.select().from(schema.simState))[0];
-  let targetFuel: number; // tank level after the refuel
+  if (!sim) throw new Error('sim_state row missing');
-  if (mode === 'forFlight') {
-    if (!opts.packageId) throw new GameActionError(400, 'packageId is required when mode is "forFlight"');
-
-    const pkgRows = await inst.db.select().from(schema.packages).where(eq(schema.packages.id, opts.packageId));
-    const pkg = pkgRows[0];
-    if (!pkg) throw new GameActionError(404, `package ${opts.packageId} not found`);
-    if (pkg.status !== 'loaded' || pkg.planeId !== plane.id) {
-      const where = pkg.planeId === plane.id ? '' : ', and it is bound to another plane';
-      throw new GameActionError(409, `only a package loaded on this plane can be refueled for (it is ${pkg.status}${where})`);
-    }
-
-    const type = PLANE_TYPES[plane.model];
-    if (!type) throw new Error(`unknown plane model ${plane.model}`); // → 500, cannot happen for seeded data
-    const origin = await airportByIcao(plane.locationIcao);
-    const dest = await airportByIcao(pkg.destIcao);
-    const distanceKm = haversineKm(origin.lat, origin.lon, dest.lat, dest.lon);
-    // Same wind-adjusted requirement flyPlane checks (v0.36.0) — departure weather vs route heading.
-    const w = weatherFor(plane.locationIcao);
-    const requiredL = requiredFuelFor(
-      type.burnPerKm * windBurnFactor(w.windKt, w.windDirDeg, initialBearingDeg(origin.lat, origin.lon, dest.lat, dest.lon)),
-      type.emptyWeightKg,
-      type.maxFuel,
-      distanceKm,
-    );
-    if (requiredL > plane.maxFuel) {
-      throw new GameActionError(409, `the leg to ${pkg.destIcao} needs ${Math.round(requiredL)} L even starting empty — it does not fit a full ${plane.maxFuel} L tank`);
-    }
-    // ISS-071: buy 150% of the requirement (capped at tank capacity) so burn variance doesn't strand
-    // the plane. The margin makes flyPlane's strict `>` check pass with room to spare; already enough
-    // → free no-op, tank untouched.
-    targetFuel = Math.min(plane.maxFuel, Math.max(plane.fuel, requiredL * 1.5));
-  } else {
-    // Exactly maxFuel (as before v0.16.0) — clients/tests compare against it with strict equality.
-    targetFuel = plane.maxFuel;
-  }
-
-  const liters = Math.max(0, targetFuel - plane.fuel);
   const account = (await inst.db.select().from(schema.account))[0];
   if (!account) throw new Error('account row missing');
-  // v0.38.0 (ISS-072): rep-scaled discount on the PRICE term only — the burn/target math above is untouched.
+  if (account.cash < REPAIR_COST) {
-  const cost = Math.round(liters * FUEL_PRICE_PER_L * (1 - repRate(account.reputation, FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT)) * 100) / 100;
+    throw new GameActionError(409, `insufficient funds: repair costs ${REPAIR_COST}, you have ${Math.round(account.cash)}`);
-  if (cost > 0 && account.cash < cost) {
-    throw new GameActionError(409, `insufficient funds: refueling costs ${cost}, you have ${Math.round(account.cash)}`);
   }
 
-  await inst.db.update(schema.planes).set({ fuel: targetFuel }).where(eq(schema.planes.id, planeId));
+  await inst.db.update(schema.planes)
-  if (cost > 0) {
+    .set({ health: 100, status: 'repairing', repairUntilSimTime: sim.clockMs + REPAIR_DURATION_MS })
-    await inst.db.update(schema.account).set({ cash: Math.round((account.cash - cost) * 100) / 100 });
+    .where(eq(schema.planes.id, planeId));
-  }
+  await inst.db.update(schema.account).set({ cash: Math.round((account.cash - REPAIR_COST) * 100) / 100 });
   await persist(inst);
-  return { cost };
+  return { cost: REPAIR_COST };
 }
 
 // --- Route helper (response convention, v0.8.0) ---

lib/game/catalog.test.ts

@@ -1,5 +1,5 @@
 import { describe, expect, it } from 'vitest';
-import { FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT, MAX_PLANE_DISCOUNT, PLANE_DISCOUNT_PER_REP, PLANE_TYPES, repRate, STARTER_MODEL } from './catalog';
+import { BROKEN_BURN_MULTIPLIER, conditionBurnMultiplier, FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT, MAX_PLANE_DISCOUNT, PLANE_DISCOUNT_PER_REP, PLANE_TYPES, repRate, STARTER_MODEL } from './catalog';
 import { STARTING_REPUTATION } from './seed';
 
 // v0.28.0 (ISS-047) — catalog sanity: the progression ladder must stay well-formed as types are added.
@@ -43,3 +43,21 @@ describe('repRate', () => {
     expect(repRate(1_000_000, FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT)).toBe(MAX_FUEL_DISCOUNT);
   });
 });
+
+// v0.39.0 (ISS-069) — the broken-state burn factor: ×BROKEN_BURN_MULTIPLIER at/below zero health, exactly 1 above it.
+describe('conditionBurnMultiplier', () => {
+  it('is exactly 1 for any positive health', () => {
+    expect(conditionBurnMultiplier(100)).toBe(1);
+    expect(conditionBurnMultiplier(42)).toBe(1);
+    expect(conditionBurnMultiplier(0.5)).toBe(1); // worn but not broken
+  });
+
+  it('is exactly BROKEN_BURN_MULTIPLIER at and below zero health', () => {
+    expect(conditionBurnMultiplier(0)).toBe(BROKEN_BURN_MULTIPLIER);
+    expect(conditionBurnMultiplier(-3)).toBe(BROKEN_BURN_MULTIPLIER); // defensive — wear clamps at 0, but the gate is <= 0
+  });
+
+  it('pins the broken multiplier at ×1.5', () => {
+    expect(BROKEN_BURN_MULTIPLIER).toBe(1.5);
+  });
+});

lib/game/catalog.ts

@@ -100,7 +100,8 @@ export const PLANE_TYPES: Record<string, PlaneType> = {
 // The plane the player starts with.
 export const STARTER_MODEL = 'atr72';
 
-// Jet-A1 fuel price in €/liter (v0.8.0): refueling cost = (maxFuel − fuel) × this.
+// Jet-A1 fuel price in €/liter (v0.8.0): top-up cost = liters × this — applied to the automatic
+// dispatch top-ups since ISS-082 (manual refuel removed).
 export const FUEL_PRICE_PER_L = 0.8;
 
 // Fraction of the catalog price paid out when selling a plane (v0.8.0).
@@ -122,9 +123,28 @@ export const FUEL_DISCOUNT_PER_REP = 0.005;
 // ponytail: balance-tunable — max refuel price discount (reached at rep ≥ 50).
 export const MAX_FUEL_DISCOUNT = 0.2;
 
+// --- Maintenance (v0.39.0, ISS-069) ---
+
+// ponytail: balance-tunable — health lost per km of landed legs (~13 mid-range EDDF↔LEMD hops to break from full).
+export const WEAR_PER_KM = 0.005;
+
+// ponytail: balance-tunable — burn multiplier for a broken plane (health ≤ 0): it still flies, just thirsty.
+export const BROKEN_BURN_MULTIPLIER = 1.5;
+
+// Broken-state burn factor for one plane's health — the third multiplicative term alongside wind at every
+// per-plane burn site (flyPlane dispatch top-up + backstop, engine landed fuel + auto-chain, live display).
+export function conditionBurnMultiplier(health: number): number {
+  return health <= 0 ? BROKEN_BURN_MULTIPLIER : 1;
+}
+
+// ponytail: balance-tunable — flat repair cost in € (per-type if balance demands it).
+export const REPAIR_COST = 1_500;
+// ponytail: balance-tunable — how long a repair grounds the plane, sim ms (3 game days).
+export const REPAIR_DURATION_MS = 3 * 86_400_000;
+
 // Snapshot shape of one catalog entry in GET /api/state (v0.10.0): `model` is the
 // id used by buy/dispatch, `label` the display name — clients compute all market
-// previews (buy price, sell payout, refuel cost) from these + the economy constants.
+// previews (buy price, sell payout) from these + the economy constants.
 export interface CatalogEntry {
   model: string;
   label: string;

lib/game/seed.test.ts

@@ -49,6 +49,7 @@ describe('buildSeed', () => {
       lat: 50.0333,
       lon: 8.5706,
       queue: [], // v0.25.0 (ISS-043) — no queued legs on first run
+      health: 100, // v0.39.0 (ISS-069) — full health on first run
     });
   });
 

lib/game/seed.ts

@@ -42,6 +42,8 @@ export interface SeedPlane {
   // Upcoming legs not yet started (v0.25.0, ISS-043) — serialized to the queue
   // column as JSON text on insert; defaults to an empty queue.
   queue?: string[];
+  // Structural health in [0, 100] (v0.39.0, ISS-069) — new planes start at full health.
+  health: number;
 }
 
 export interface SeedPackage {
@@ -237,6 +239,7 @@ export function buildSeed(input: {
     lat: hub.lat,
     lon: hub.lon,
     queue: [], // no queued legs on first run (v0.25.0)
+    health: 100, // full health on first run (v0.39.0, ISS-069)
   };
 
   const count = PACKAGE_COUNT_MIN + Math.floor(rng() * (PACKAGE_COUNT_MAX - PACKAGE_COUNT_MIN + 1));

lib/game/state.ts

@@ -3,7 +3,7 @@ import { haversineKm, initialBearingDeg } from '@/lib/geo';
 import { weatherFor } from '@/lib/weather';
 import { getGameDb } from '@/lib/db/client';
 import * as schema from '@/lib/db/schema';
-import { catalogEntries, FUEL_PRICE_PER_L, PLANE_TYPES, SELL_FRACTION, type CatalogEntry } from './catalog';
+import { conditionBurnMultiplier, catalogEntries, FUEL_PRICE_PER_L, PLANE_TYPES, SELL_FRACTION, type CatalogEntry } from './catalog';
 import { fuelAtWeighted, progressAt, positionAt, windBurnFactor } from '@/lib/sim/movement';
 
 // Read-only game-state snapshot for client polling (GET /api/state).
@@ -11,7 +11,8 @@ import { fuelAtWeighted, progressAt, positionAt, windBurnFactor } from '@/lib/si
 export interface PlaneState {
   id: string;
   model: string;
-  status: 'available' | 'flying';
+  // v0.39.0 (ISS-069): 'repairing' = grounded in the shop until repairUntilSimTime passes.
+  status: 'available' | 'flying' | 'repairing';
   fuel: number;
   maxFuel: number;
   locationIcao: string;
@@ -28,6 +29,11 @@ export interface PlaneState {
   // Upcoming legs NOT yet started (v0.25.0, ISS-043) — ordered ICAOs; the active
   // leg is destIcao. The engine auto-chains queue[0] on landing when fuel covers it.
   queue: string[];
+  // Structural health in [0, 100] (v0.39.0, ISS-069) — wears down with distance flown; at 0 the
+  // plane is broken and burns BROKEN_BURN_MULTIPLIER × more fuel until repaired.
+  health: number;
+  // Sim-clock epoch ms when an active repair finishes (v0.39.0, ISS-069); null when not in repair.
+  repairUntilSimTime: number | null;
 }
 
 // Parse the planes.queue JSON column into an ICAO list (v0.25.0). Guards against
@@ -68,7 +74,7 @@ export interface StateSnapshot {
   planes: PlaneState[];
   packages: PackageState[];
   // Market reference data (v0.10.0) — static per build, sent with every snapshot so
-  // the client can compute buy/sell/refuel previews without a separate endpoint.
+  // the client can compute buy/sell previews without a separate endpoint.
   catalog: CatalogEntry[];
   fuelPricePerL: number;
   sellFraction: number;
@@ -107,10 +113,12 @@ export async function getStateSnapshot(): Promise<StateSnapshot> {
     const pos = positionAt(from.lat, from.lon, to.lat, to.lon, progress);
     // Wind-adjusted burn (v0.36.0) — weather is a pure function of the departure ICAO, so this
     // recomputes exactly the factor the engine used for the leg; no stored state needed.
+    // v0.39.0 (ISS-069): broken planes burn BROKEN_BURN_MULTIPLIER × more — p.health is frozen at
+    // departure (wear lands only), so this stays bit-consistent with the engine's landed fuel.
     const w = weatherFor(p.locationIcao);
     return { ...pos, fuel: fuelAtWeighted(
       p.fuel,
-      type.burnPerKm * windBurnFactor(w.windKt, w.windDirDeg, initialBearingDeg(from.lat, from.lon, to.lat, to.lon)),
+      type.burnPerKm * windBurnFactor(w.windKt, w.windDirDeg, initialBearingDeg(from.lat, from.lon, to.lat, to.lon)) * conditionBurnMultiplier(p.health),
       type.emptyWeightKg,
       type.maxFuel,
       distanceKm,
@@ -140,6 +148,8 @@ export async function getStateSnapshot(): Promise<StateSnapshot> {
         lat: live?.lat ?? p.lat,
         lon: live?.lon ?? p.lon,
         queue: parseIcaoQueue(p.queue),
+        health: p.health, // v0.39.0 (ISS-069) — stored value; wear accumulates at landing only
+        repairUntilSimTime: p.repairUntilSimTime,
       };
     }),
     packages: packageRows.map((p) => ({

lib/mapData.test.ts

@@ -34,8 +34,8 @@ describe('planesGeoJson', () => {
     const fc = planesGeoJson(
       snapshot({
         planes: [
-          { id: 'plane-starter', model: 'atr72', status: 'available', fuel: 6300, maxFuel: 6300, locationIcao: 'EDDF', locationName: 'Frankfurt Main Airport', destIcao: null, destName: null, departureSimTime: null, lat: 50.03, lon: 8.56, queue: [] },
+          { id: 'plane-starter', model: 'atr72', status: 'available', fuel: 6300, maxFuel: 6300, locationIcao: 'EDDF', locationName: 'Frankfurt Main Airport', destIcao: null, destName: null, departureSimTime: null, lat: 50.03, lon: 8.56, health: 100, repairUntilSimTime: null, queue: [] },
-          { id: 'plane-2', model: 'atr72', status: 'flying', fuel: 4000, maxFuel: 6300, locationIcao: 'EDDF', locationName: 'Frankfurt Main Airport', destIcao: 'EDDV', destName: 'Hannover Airport', departureSimTime: 1000, lat: 51.2, lon: 9.1, queue: [] },
+          { id: 'plane-2', model: 'atr72', status: 'flying', fuel: 4000, maxFuel: 6300, locationIcao: 'EDDF', locationName: 'Frankfurt Main Airport', destIcao: 'EDDV', destName: 'Hannover Airport', departureSimTime: 1000, lat: 51.2, lon: 9.1, health: 100, repairUntilSimTime: null, queue: [] },
         ],
       }),
     );
@@ -61,7 +61,7 @@ describe('planesGeoJson', () => {
       snapshot({
         catalog: [],
         planes: [
-          { id: 'p1', model: 'mystery', status: 'available', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'x', destIcao: null, destName: null, departureSimTime: null, lat: 0, lon: 0, queue: [] },
+          { id: 'p1', model: 'mystery', status: 'available', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'x', destIcao: null, destName: null, departureSimTime: null, lat: 0, lon: 0, health: 100, repairUntilSimTime: null, queue: [] },
         ],
       }),
     );
@@ -72,7 +72,7 @@ describe('planesGeoJson', () => {
     const fc = planesGeoJson(
       snapshot({
         planes: [
-          { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'x', destIcao: null, destName: null, departureSimTime: 0, lat: 0, lon: 0, queue: [] },
+          { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'x', destIcao: null, destName: null, departureSimTime: 0, lat: 0, lon: 0, health: 100, repairUntilSimTime: null, queue: [] },
         ],
       }),
     );
@@ -89,7 +89,7 @@ describe('routesGeoJson (v0.12.0 — one line per flying plane\'s current leg)',
     const fc = routesGeoJson(
       snapshot({
         planes: [
-          { id: 'p1', model: 'atr72', status: 'available', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: null, destName: null, departureSimTime: null, lat: 50.03, lon: 8.56, queue: [] },
+          { id: 'p1', model: 'atr72', status: 'available', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: null, destName: null, departureSimTime: null, lat: 50.03, lon: 8.56, health: 100, repairUntilSimTime: null, queue: [] },
         ],
       }),
       AIRPORTS,
@@ -101,7 +101,7 @@ describe('routesGeoJson (v0.12.0 — one line per flying plane\'s current leg)',
     const fc = routesGeoJson(
       snapshot({
         planes: [
-          { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: 'EHAM', destName: 'A', departureSimTime: 0, lat: 51, lon: 9, queue: [] },
+          { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: 'EHAM', destName: 'A', departureSimTime: 0, lat: 51, lon: 9, health: 100, repairUntilSimTime: null, queue: [] },
         ],
       }),
       AIRPORTS,
@@ -118,7 +118,7 @@ describe('routesGeoJson (v0.12.0 — one line per flying plane\'s current leg)',
     const fc = routesGeoJson(
       snapshot({
         planes: [
-          { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'ZZZZ', locationName: '?', destIcao: 'EDDV', destName: 'H', departureSimTime: 0, lat: 0, lon: 0, queue: [] },
+          { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'ZZZZ', locationName: '?', destIcao: 'EDDV', destName: 'H', departureSimTime: 0, lat: 0, lon: 0, health: 100, repairUntilSimTime: null, queue: [] },
         ],
       }),
       AIRPORTS,
@@ -130,8 +130,8 @@ describe('routesGeoJson (v0.12.0 — one line per flying plane\'s current leg)',
     const fc = routesGeoJson(
       snapshot({
         planes: [
-          { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: 'EDDV', destName: 'H', departureSimTime: 0, lat: 51, lon: 9, queue: [] },
+          { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: 'EDDV', destName: 'H', departureSimTime: 0, lat: 51, lon: 9, health: 100, repairUntilSimTime: null, queue: [] },
-          { id: 'p2', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDV', locationName: 'H', destIcao: 'EHAM', destName: 'A', departureSimTime: 0, lat: 52.4, lon: 9.6, queue: [] },
+          { id: 'p2', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDV', locationName: 'H', destIcao: 'EHAM', destName: 'A', departureSimTime: 0, lat: 52.4, lon: 9.6, health: 100, repairUntilSimTime: null, queue: [] },
         ],
       }),
       AIRPORTS,
@@ -140,11 +140,37 @@ describe('routesGeoJson (v0.12.0 — one line per flying plane\'s current leg)',
   });
 });
 
-describe('queuedRoutesGeoJson (ISS-043 v0.26.0 — dotted queue line: dest → queued legs only)', () => {
+describe('queuedRoutesGeoJson (ISS-043 v0.26.0 — dotted queue line: dest → queued legs only; ISS-077 v0.41.0 — grounded queues too)', () => {
-  it('draws nothing for a grounded plane, even with a non-empty queue', () => {
+  it('grounded plane with a non-empty queue → one feature chaining locationIcao → queued legs (ISS-077)', () => {
     const fc = queuedRoutesGeoJson(
       [
-        { id: 'p1', model: 'atr72', status: 'available', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: null, destName: null, departureSimTime: null, lat: 50.03, lon: 8.56, queue: ['EHAM'] },
+        // Pre-built route while grounded: the line starts at the plane's current airport, not at any dest.
+        { id: 'p1', model: 'atr72', status: 'available', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: null, destName: null, departureSimTime: null, lat: 50.03, lon: 8.56, health: 100, repairUntilSimTime: null, queue: ['EHAM'] },
+      ],
+      AIRPORTS,
+    );
+    expect(fc.features).toHaveLength(1);
+    expect(fc.features[0].properties).toEqual({ planeId: 'p1' });
+    const coords = fc.features[0].geometry.coordinates;
+    expect(coords.length).toBe(ROUTE_ARC_SEGMENTS + 1); // one arc, exact endpoints
+    expect(coords[0]).toEqual([8.56, 50.03]); // starts at the plane's airport (EDDF)
+    expect(coords[coords.length - 1]).toEqual([4.76, 52.31]); // ends at the queued airport (EHAM)
+  });
+
+  it('skips a grounded plane whose locationIcao is missing from the airport index', () => {
+    const fc = queuedRoutesGeoJson(
+      [
+        { id: 'p1', model: 'atr72', status: 'available', fuel: 1, maxFuel: 2, locationIcao: 'ZZZZ', locationName: '?', destIcao: null, destName: null, departureSimTime: null, lat: 0, lon: 0, health: 100, repairUntilSimTime: null, queue: ['EHAM'] },
+      ],
+      AIRPORTS,
+    );
+    expect(fc.features).toHaveLength(0);
+  });
+
+  it('draws nothing for a repairing plane, even with a non-empty queue', () => {
+    const fc = queuedRoutesGeoJson(
+      [
+        { id: 'p1', model: 'atr72', status: 'repairing', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: null, destName: null, departureSimTime: null, lat: 50.03, lon: 8.56, health: 0, repairUntilSimTime: 1000, queue: ['EHAM'] },
       ],
       AIRPORTS,
     );
@@ -154,7 +180,7 @@ describe('queuedRoutesGeoJson (ISS-043 v0.26.0 — dotted queue line: dest → q
   it('draws nothing for a flying plane with an empty queue', () => {
     const fc = queuedRoutesGeoJson(
       [
-        { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: 'EHAM', destName: 'A', departureSimTime: 0, lat: 51, lon: 9, queue: [] },
+        { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: 'EHAM', destName: 'A', departureSimTime: 0, lat: 51, lon: 9, health: 100, repairUntilSimTime: null, queue: [] },
       ],
       AIRPORTS,
     );
@@ -165,7 +191,7 @@ describe('queuedRoutesGeoJson (ISS-043 v0.26.0 — dotted queue line: dest → q
     const fc = queuedRoutesGeoJson(
       [
         // Active leg EDDF→EHAM stays in routesGeoJson; the queue line is ONLY EHAM → EDDV → LEMD.
-        { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: 'EHAM', destName: 'A', departureSimTime: 0, lat: 51, lon: 9, queue: ['EDDV', 'LEMD'] },
+        { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: 'EHAM', destName: 'A', departureSimTime: 0, lat: 51, lon: 9, health: 100, repairUntilSimTime: null, queue: ['EDDV', 'LEMD'] },
       ],
       AIRPORTS,
     );
@@ -182,24 +208,27 @@ describe('queuedRoutesGeoJson (ISS-043 v0.26.0 — dotted queue line: dest → q
   it('skips a plane whose dest or a queued ICAO is missing from the airport index', () => {
     const fc = queuedRoutesGeoJson(
       [
-        { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: 'ZZZZ', destName: '?', departureSimTime: 0, lat: 51, lon: 9, queue: ['EHAM'] },
+        { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: 'ZZZZ', destName: '?', departureSimTime: 0, lat: 51, lon: 9, health: 100, repairUntilSimTime: null, queue: ['EHAM'] },
-        { id: 'p2', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: 'EHAM', destName: 'A', departureSimTime: 0, lat: 51, lon: 9, queue: ['ZZZZ'] },
+        { id: 'p2', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: 'EHAM', destName: 'A', departureSimTime: 0, lat: 51, lon: 9, health: 100, repairUntilSimTime: null, queue: ['ZZZZ'] },
       ],
       AIRPORTS,
     );
     expect(fc.features).toHaveLength(0);
   });
 
-  it('one feature per qualifying plane — grounded and empty-queue planes draw nothing', () => {
+  it('one feature per qualifying plane — flying and grounded queues draw; empty-queue planes do not', () => {
     const fc = queuedRoutesGeoJson(
       [
-        { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: 'EHAM', destName: 'A', departureSimTime: 0, lat: 51, lon: 9, queue: ['LEMD'] },
+        { id: 'p1', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EDDF', locationName: 'F', destIcao: 'EHAM', destName: 'A', departureSimTime: 0, lat: 51, lon: 9, health: 100, repairUntilSimTime: null, queue: ['LEMD'] },
-        { id: 'p2', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EHAM', locationName: 'A', destIcao: 'EDDV', destName: 'H', departureSimTime: 0, lat: 52.3, lon: 4.7, queue: [] },
+        { id: 'p2', model: 'atr72', status: 'flying', fuel: 1, maxFuel: 2, locationIcao: 'EHAM', locationName: 'A', destIcao: 'EDDV', destName: 'H', departureSimTime: 0, lat: 52.3, lon: 4.7, health: 100, repairUntilSimTime: null, queue: [] },
-        { id: 'p3', model: 'atr72', status: 'available', fuel: 1, maxFuel: 2, locationIcao: 'EDDV', locationName: 'H', destIcao: null, destName: null, departureSimTime: null, lat: 52.46, lon: 9.68, queue: ['LEMD'] },
+        { id: 'p3', model: 'atr72', status: 'available', fuel: 1, maxFuel: 2, locationIcao: 'EDDV', locationName: 'H', destIcao: null, destName: null, departureSimTime: null, lat: 52.46, lon: 9.68, health: 100, repairUntilSimTime: null, queue: ['LEMD'] },
       ],
       AIRPORTS,
     );
-    expect(fc.features.map((f) => f.properties.planeId)).toEqual(['p1']);
+    expect(fc.features.map((f) => f.properties.planeId)).toEqual(['p1', 'p3']); // p2 has an empty queue
+    const p3 = fc.features[1].geometry.coordinates;
+    expect(p3[0]).toEqual([9.68, 52.46]); // grounded chain starts at the plane's airport (EDDV)
+    expect(p3[p3.length - 1]).toEqual([-3.56, 40.47]); // …and ends at the queued airport (LEMD)
   });
 });
 
@@ -254,6 +283,12 @@ describe('hoverTraceGeoJson (ISS-040 v0.23.2 — on-board package trace from the
   it('returns an empty collection when the dest airport is missing from the dataset', () => {
     expect(hoverTraceGeoJson({ lat: 0, lon: 0 }, 'ZZZZ', AIRPORTS)).toEqual({ type: 'FeatureCollection', features: [] });
   });
+
+  // ISS-077 (v0.41.0): a flying carrier's trace starts at its landing airport — when that IS the
+  // package's destination there is nothing to draw (the solid active-leg layer covers it).
+  it('returns an empty collection when the start point equals the dest airport', () => {
+    expect(hoverTraceGeoJson(AIRPORTS.get('EHAM')!, 'EHAM', AIRPORTS)).toEqual({ type: 'FeatureCollection', features: [] });
+  });
 });
 
 describe('greatCircleArc (v0.12.2 — curved route traces)', () => {

lib/mapData.ts

@@ -10,7 +10,8 @@ import { positionAt } from './sim/movement';
 export interface PlaneFeatureProps {
   id: string;
   modelLabel: string;
-  status: 'available' | 'flying';
+  // v0.39.0 (ISS-069): 'repairing' planes render on the grounded layer (flying === false).
+  status: 'available' | 'flying' | 'repairing';
   fuelText: string; // "1234 / 6300 L"
   routeText: string; // "Origin → Destination" while flying, '' when grounded
   flying: boolean;
@@ -115,7 +116,10 @@ export function hoverRouteGeoJson(
 // ISS-040 (v0.23.2): the on-board package hover trace — same shape as hoverRouteGeoJson but the
 // start is a live COORDINATE (the carrier plane's current position), not an airport ICAO: once the
 // plane has departed with cargo still loaded, the preview must begin where it actually is. Empty
-// collection when the destination is missing from the dataset — never guessed.
+// collection when the destination is missing from the dataset — never guessed. ISS-077 (v0.41.0):
+// also empty when the start point IS the destination airport itself (a flying carrier's trace now
+// starts at its landing airport, which can equal the package's dest) — nothing to draw there; the
+// solid active-leg layer covers that case.
 export function hoverTraceGeoJson(
   from: AirportCoord,
   toIcao: string,
@@ -123,6 +127,7 @@ export function hoverTraceGeoJson(
 ): FeatureCollection<MapLineFeature> {
   const to = airportsByIcao.get(toIcao);
   if (!to) return EMPTY_LINES;
+  if (from.lat === to.lat && from.lon === to.lon) return EMPTY_LINES; // start == dest — zero-length trace
   return {
     type: 'FeatureCollection',
     features: [
@@ -165,19 +170,25 @@ export function routesGeoJson(
   return { type: 'FeatureCollection', features };
 }
 
-// ISS-043 (v0.26.0): the dotted queue line — one LineString per FLYING plane with a non-empty
+// ISS-043 (v0.26.0): the dotted queue line — one LineString per plane with a non-empty queue,
-// queue, chaining dest → queue[0] → … → queue[n−1]: ONLY the not-yet-started legs (the active
+// chaining the not-yet-started legs: a FLYING plane starts at its active leg's destination
-// leg locationIcao→dest stays in routesGeoJson's solid layer). Arcs are concatenated with the
+// (dest → queue[0] → …; the active leg locationIcao→dest stays in routesGeoJson's solid layer),
-// shared joint point dropped once. A plane is skipped — never guessed — when its dest or any
+// and ISS-077 (v0.41.0) extends it to GROUNDED ('available') planes, which start at their current
-// queued ICAO is missing from the airport index; empty collection when nothing qualifies.
+// airport (locationIcao → queue[0] → …). 'repairing' planes draw nothing — they can't fly. Arcs are
+// concatenated with the shared joint point dropped once. A plane is skipped — never guessed — when
+// its first point or any queued ICAO is missing from the airport index; empty collection when
+// nothing qualifies.
 export function queuedRoutesGeoJson(
   planes: PlaneState[],
   airportsByIcao: ReadonlyMap<string, AirportCoord>,
 ): FeatureCollection<MapLineFeature> {
   const features: MapLineFeature[] = [];
   for (const p of planes) {
-    if (p.status !== 'flying' || !p.destIcao || p.queue.length === 0) continue;
+    if (p.queue.length === 0) continue;
-    const pts = [p.destIcao, ...p.queue].map((icao) => airportsByIcao.get(icao));
+    // First point of the chain: a flying plane's landing airport, a grounded one's current airport.
+    const firstIcao = p.status === 'flying' ? p.destIcao : p.status === 'available' ? p.locationIcao : null;
+    if (!firstIcao) continue;
+    const pts = [firstIcao, ...p.queue].map((icao) => airportsByIcao.get(icao));
     if (pts.some((c) => c === undefined)) continue; // an endpoint is missing from the dataset — skip
     const coords: [number, number][] = [];
     for (let i = 0; i < pts.length - 1; i++) {

lib/openapi.test.ts

@@ -14,7 +14,7 @@ describe('OpenAPI spec', () => {
       '/api/planes/{planeId}/fly',
       '/api/planes/{planeId}/queue', // v0.25.0 (ISS-043)
       '/api/planes/{planeId}/queue/cancel', // v0.25.0 (ISS-043)
-      '/api/planes/{planeId}/refuel',
+      '/api/planes/{planeId}/repair', // v0.39.0 (ISS-069)
       '/api/sim',
       '/api/state',
       '/api/version',
@@ -115,6 +115,7 @@ describe('OpenAPI spec', () => {
       'destIcao',
       'destName',
       'fuel',
+      'health', // v0.39.0 (ISS-069) — structural health in [0, 100]
       'id',
       'lat',
       'locationIcao',
@@ -123,6 +124,7 @@ describe('OpenAPI spec', () => {
       'maxFuel',
       'model',
       'queue', // v0.25.0 (ISS-043) — upcoming legs not yet started
+      'repairUntilSimTime', // v0.39.0 (ISS-069) — active repair gate; null when not repairing
       'status',
     ]);
 
@@ -192,7 +194,7 @@ describe('OpenAPI spec', () => {
       '/api/planes/{planeId}/queue/cancel', // v0.25.0 (ISS-043)
       '/api/market/buy-plane',
       '/api/market/sell-plane',
-      '/api/planes/{planeId}/refuel',
+      '/api/planes/{planeId}/repair', // v0.39.0 (ISS-069)
     ]) {
       const ok = post(p).responses['200'] as { content: Record<string, { schema: { $ref: string } }> };
       expect(ok.content['application/json'].schema.$ref).toBe('#/components/schemas/StateSnapshot');
@@ -207,10 +209,9 @@ describe('OpenAPI spec', () => {
     expect(errorCodes('/api/planes/{planeId}/queue/cancel')).toEqual(['400', '404']); // v0.25.0
     expect(errorCodes('/api/market/buy-plane')).toEqual(['400', '409']);
     expect(errorCodes('/api/market/sell-plane')).toEqual(['400', '404', '409']);
-    expect(errorCodes('/api/planes/{planeId}/refuel')).toEqual(['400', '404', '409']); // v0.16.0 optional body
+    expect(errorCodes('/api/planes/{planeId}/repair')).toEqual(['404', '409']); // v0.39.0 (ISS-069) — no body, so no 400
 
-    // Request bodies: load/fly/buy/sell take their dedicated schemas; abandon takes none;
+    // Request bodies: load/fly/buy/sell take their dedicated schemas; abandon and repair take none.
-    // refuel's is OPTIONAL (v0.16.0) — no body still means "fill to full".
     expect(post('/api/packages/{id}/load').requestBody?.content['application/json'].schema.$ref).toBe(
       '#/components/schemas/LoadPackageRequest',
     );
@@ -230,9 +231,7 @@ describe('OpenAPI spec', () => {
       '#/components/schemas/SellPlaneRequest',
     );
     expect(post('/api/packages/{id}/abandon').requestBody).toBeUndefined();
-    const refuelBody = post('/api/planes/{planeId}/refuel').requestBody;
+    expect(post('/api/planes/{planeId}/repair').requestBody).toBeUndefined(); // v0.39.0 (ISS-069) — no body, like abandon
-    expect(refuelBody?.content['application/json'].schema.$ref).toBe('#/components/schemas/RefuelRequest');
-    expect(refuelBody?.required).toBe(false); // optional — no body still means "fill to full"
 
     // Path parameters are declared on the parameterized routes.
     const paramNames = (p: string) => post(p).parameters?.map((x) => x.name);
@@ -241,7 +240,7 @@ describe('OpenAPI spec', () => {
     expect(paramNames('/api/planes/{planeId}/fly')).toEqual(['planeId']);
     expect(paramNames('/api/planes/{planeId}/queue')).toEqual(['planeId']); // v0.25.0 (ISS-043)
     expect(paramNames('/api/planes/{planeId}/queue/cancel')).toEqual(['planeId']); // v0.25.0 (ISS-043)
-    expect(paramNames('/api/planes/{planeId}/refuel')).toEqual(['planeId']);
+    expect(paramNames('/api/planes/{planeId}/repair')).toEqual(['planeId']); // v0.39.0 (ISS-069)
 
     // Request schema shapes.
     const load = openApiSpec.components.schemas.LoadPackageRequest;
@@ -263,11 +262,5 @@ describe('OpenAPI spec', () => {
     const sell = openApiSpec.components.schemas.SellPlaneRequest;
     expect(sell.required).toEqual(['planeId']);
     expect(sell.properties.planeId.type).toBe('string');
-
-    // RefuelRequest (v0.16.0): both fields optional — no body / {} means "full".
-    const refuel = openApiSpec.components.schemas.RefuelRequest;
-    expect((refuel as { required?: string[] }).required ?? []).toEqual([]);
-    expect(((refuel.properties.mode) as { enum: string[] }).enum.sort()).toEqual(['forFlight', 'full']);
-    expect(refuel.properties.packageId.type).toBe('string');
   });
 });

lib/openapi.ts

@@ -8,7 +8,7 @@ export const openApiSpec = {
   info: {
     title: 'Flight Ops API',
     description:
-      'JSON API for Flight Ops — EU airport data for the map, the live game-state snapshot, player actions (load / fly / abandon / buy / sell / refuel), and app metadata. Every action endpoint ticks the sim clock first and returns the full state snapshot on success.',
+      'JSON API for Flight Ops — EU airport data for the map, the live game-state snapshot, player actions (load / fly / abandon / buy / sell), and app metadata. Every action endpoint ticks the sim clock first and returns the full state snapshot on success.',
     // Sourced from package.json so it stays in sync with every version bump.
     version: pkg.version,
   },
@@ -37,7 +37,7 @@ export const openApiSpec = {
       get: {
         summary: 'Game state snapshot',
         description:
-          'Full current game state for client polling — account, sim clock, planes and packages, plus the static market reference data (catalog + economy constants) so clients can compute buy/sell/refuel previews locally. Tick-on-read: each call first advances the sim clock by (real time since last read) × timeScale (clamped per tick), so expiry/delivery/spawn are always applied before the snapshot is returned.',
+          'Full current game state for client polling — account, sim clock, planes and packages, plus the static market reference data (catalog + economy constants) so clients can compute buy/sell previews locally. Tick-on-read: each call first advances the sim clock by (real time since last read) × timeScale (clamped per tick), so expiry/delivery/spawn are always applied before the snapshot is returned.',
         operationId: 'getState',
         responses: {
           200: {
@@ -194,7 +194,7 @@ export const openApiSpec = {
       post: {
         summary: 'Fly a plane to an airport',
         description:
-          'Manual flight (v0.12.0): send a GROUNDED ("available") plane to any known airport — its loaded packages\' destinations or pure repositioning. The plane becomes "flying" with departureSimTime = current sim clock and destIcao set; the engine flies it analytically, delivers bound cargo on arrival, and grounds it there.',
+          'Manual flight (v0.12.0): send a GROUNDED ("available") plane to any known airport — its loaded packages\' destinations or pure repositioning. The plane becomes "flying" with departureSimTime = current sim clock and destIcao set; the engine flies it analytically, delivers bound cargo on arrival, and grounds it there. ISS-082 (v0.42.0): dispatch auto-refuels first — the tank is topped up to min(maxFuel, max(fuel, 1.5 × required)) at fuelPricePerL per liter minus a reputation-scaled discount, deducted from cash; no separate refuel endpoint exists anymore.',
         operationId: 'flyPlane',
         parameters: [
           { name: 'planeId', in: 'path', required: true, schema: { type: 'string' } },
@@ -223,7 +223,7 @@ export const openApiSpec = {
           },
           409: {
             description:
-              'Plane not grounded, or insufficient fuel for the leg (v0.16.0 weight-proportional burn — the fuel required to cover the great-circle distance arriving empty)',
+              'Plane not grounded, or the leg does not fit even a FULL tank (v0.16.0 weight-proportional burn — the fuel required to cover the great-circle distance arriving empty; dispatch auto-refuels up to min(maxFuel, max(fuel, 1.5 × required)) first, ISS-082), or cash is insufficient for that top-up',
             content: { 'application/json': { schema: { $ref: '#/components/schemas/Error' } } },
           },
         },
@@ -233,7 +233,7 @@ export const openApiSpec = {
       post: {
         summary: 'Queue a flight leg for a plane',
         description:
-          'Append a NOT-yet-started leg to the plane\'s flight queue (v0.25.0, ISS-043). Works whether the plane is grounded or flying — you can pre-build a route; the active leg still starts via /fly and nothing auto-starts here. On landing, the engine auto-chains the first queued leg when fuel covers it (otherwise the plane grounds with the queue kept intact for refuel + re-dispatch).',
+          'Append a NOT-yet-started leg to the plane\'s flight queue (v0.25.0, ISS-043). Works whether the plane is grounded or flying — you can pre-build a route; the active leg still starts via /fly and nothing auto-starts here. On landing, the engine auto-chains the first queued leg when fuel covers it — with a short tank it auto-refuels to 150% of the requirement (capped at tank capacity) when cash allows (ISS-082); only an unaffordable top-up grounds the plane with the queue kept intact for a later dispatch.',
         operationId: 'queueLeg',
         parameters: [
           { name: 'planeId', in: 'path', required: true, schema: { type: 'string' } },
@@ -366,39 +366,26 @@ export const openApiSpec = {
         },
       },
     },
-    '/api/planes/{planeId}/refuel': {
+    '/api/planes/{planeId}/repair': {
       post: {
-        summary: 'Refuel a grounded plane',
+        summary: 'Repair a grounded plane',
         description:
-          'Refuel a grounded plane at the fuel price per added liter, deducted from cash (v0.8.0); the per-liter price is reduced by a reputation-scaled discount (v0.38.0, ISS-072 — higher reputation refuels cheaper; no discount at the starting reputation). The body is optional (v0.16.0): no body or mode "full" fills to maxFuel; mode "forFlight" with packageId buys 150% of the weather-adjusted fuel required for that loaded package\'s destination leg, capped at tank capacity — liters = min(maxFuel, max(current fuel, 1.5 × required)) − current fuel, where required is the weight-proportional burn model over the great-circle distance with a ±20% wind adjustment (v0.36.0).',
+          'Restore a worn-out plane to full health for the flat repair cost (v0.39.0, ISS-069): the plane is grounded in "repairing" status until 3 sim days pass, when the engine\'s tick flips it back to "available". While repairing it cannot load, fly or be sold; a broken plane (health ≤ 0) still flies but burns 50% more fuel. A full-health repair is a free no-op (cost 0). No body.',
-        operationId: 'refuelPlane',
+        operationId: 'repairPlane',
         parameters: [
           { name: 'planeId', in: 'path', required: true, schema: { type: 'string' } },
         ],
-        requestBody: {
-          required: false,
-          content: {
-            'application/json': {
-              schema: { $ref: '#/components/schemas/RefuelRequest' },
-            },
-          },
-        },
         responses: {
           200: {
-            description: 'Refueled — full state snapshot (fuel raised by exactly the added liters, cash reduced by the cost)',
+            description: 'Repair started (or free no-op) — full state snapshot (health 100, status "repairing" with the gate set, cash reduced by the flat cost)',
             content: { 'application/json': { schema: { $ref: '#/components/schemas/StateSnapshot' } } },
           },
-          400: {
-            description: 'Invalid body (not an object, unknown field, unknown mode, or forFlight without packageId)',
-            content: { 'application/json': { schema: { $ref: '#/components/schemas/Error' } } },
-          },
           404: {
-            description: 'Unknown plane id (or unknown package id in forFlight mode)',
+            description: 'Unknown plane id',
             content: { 'application/json': { schema: { $ref: '#/components/schemas/Error' } } },
           },
           409: {
-            description:
+            description: 'Plane is not grounded (flying or already repairing), or cash is insufficient for the repair cost',
-              'Plane is flying, the package is not loaded on this plane (or is expired), the leg does not fit a full tank, or cash is insufficient for the refuel',
             content: { 'application/json': { schema: { $ref: '#/components/schemas/Error' } } },
           },
         },
@@ -476,7 +463,7 @@ export const openApiSpec = {
             description: 'Aircraft catalog (v0.10.0) — static per build, one entry per plane type.',
             items: { $ref: '#/components/schemas/CatalogEntry' },
           },
-          fuelPricePerL: { type: 'number', description: 'Jet-A1 price in €/liter; refuel cost = (maxFuel − fuel) × this, reduced by a reputation-scaled discount at refuel time (v0.38.0).' },
+          fuelPricePerL: { type: 'number', description: 'Jet-A1 price in €/liter; the automatic dispatch top-up costs liters × this, reduced by a reputation-scaled discount at refuel time (v0.38.0) — ISS-082 (v0.42.0): it now applies to the auto-refuel on /fly and the engine\'s chained-leg top-ups.' },
           sellFraction: { type: 'number', description: 'Fraction of the catalog price paid out when selling a plane.' },
         },
         required: ['account', 'simState', 'planes', 'packages', 'catalog', 'fuelPricePerL', 'sellFraction'],
@@ -567,22 +554,6 @@ export const openApiSpec = {
         },
         required: ['planeId'],
       },
-      RefuelRequest: {
-        type: 'object',
-        description:
-          'Optional refuel body (v0.16.0) — omit it entirely or send {} to fill the tank; both fields are optional.',
-        properties: {
-          mode: {
-            enum: ['full', 'forFlight'],
-            description:
-              '"full" (default) fills the tank to maxFuel; "forFlight" buys 150% of the weather-adjusted fuel required for one loaded package\'s destination leg, capped at tank capacity (v0.36.0).',
-          },
-          packageId: {
-            type: 'string',
-            description: 'Required with mode "forFlight": a package LOADED on this plane — its destIcao is the refuel target.',
-          },
-        },
-      },
       Error: {
         type: 'object',
         properties: {
@@ -595,7 +566,7 @@ export const openApiSpec = {
         properties: {
           id: { type: 'string' },
           model: { type: 'string' },
-          status: { enum: ['available', 'flying'] },
+          status: { enum: ['available', 'flying', 'repairing'] }, // v0.39.0 (ISS-069) — "repairing" = grounded in the shop until repairUntilSimTime passes
           fuel: { type: 'number' },
           maxFuel: { type: 'number' },
           locationIcao: { type: 'string' },
@@ -620,6 +591,16 @@ export const openApiSpec = {
             description:
               'Upcoming flight legs NOT yet started (v0.25.0) — ordered ICAOs; the active leg is destIcao. The engine auto-chains queue[0] on landing when fuel covers it.',
           },
+          health: {
+            type: 'number',
+            description:
+              'Structural health in [0, 100] (v0.39.0) — wears down by a fixed amount per km of landed legs; at 0 the plane is broken and burns 50% more fuel until repaired.',
+          },
+          repairUntilSimTime: {
+            type: ['integer', 'null'],
+            description:
+              'Sim-clock epoch ms when an active repair finishes (v0.39.0) — set with status "repairing", cleared by the engine\'s flip-back; null when not in repair.',
+          },
         },
         required: [
           'id',
@@ -635,6 +616,8 @@ export const openApiSpec = {
           'lat',
           'lon',
           'queue',
+          'health', // v0.39.0 (ISS-069) — structural health in [0, 100]
+          'repairUntilSimTime', // v0.39.0 (ISS-069) — active repair gate; null when not repairing
         ],
       },
       PackageState: {

lib/sim/engine.test.ts

@@ -8,7 +8,7 @@ import * as schema from '@/lib/db/schema';
 import { loadAirportsGeoJson } from '@/lib/airports';
 import { haversineKm, initialBearingDeg } from '@/lib/geo';
 import { weatherFor } from '@/lib/weather';
-import { PLANE_TYPES } from '@/lib/game/catalog';
+import { BROKEN_BURN_MULTIPLIER, conditionBurnMultiplier, FUEL_DISCOUNT_PER_REP, FUEL_PRICE_PER_L, MAX_FUEL_DISCOUNT, PLANE_TYPES, repRate, WEAR_PER_KM } from '@/lib/game/catalog';
 import { SPECIALS } from '@/lib/game/specials';
 import { MARKET_TARGET_OPEN_PACKAGES, mulberry32 } from '@/lib/game/seed';
 import { arrivalTimeFor, fuelAtWeighted, requiredFuelFor, windBurnFactor } from './movement';
@@ -16,6 +16,7 @@ import {
   clampTimeScale,
   deliverPackages,
   expirePackages,
+  finishRepairs,
   MAX_TICK_ELAPSED_MS,
   MAX_TIME_SCALE,
   MIN_TIME_SCALE,
@@ -297,19 +298,65 @@ describe('deliverPackages (v0.12.0 arrival delivery)', () => {
     expect(JSON.parse(plane.queue)).toEqual(['EDDV']); // first leg consumed, rest kept in order
   });
 
-  it('grounds when fuel cannot cover the next queued leg, keeping the queue intact', async () => {
+  it('auto-refuels a short tank and chains the next queued leg when cash allows (ISS-082)', async () => {
-    const { inst, from, to, km, type } = await setupFlight('chain-nofuel.db');
+    const { inst, from, to, km, type } = await setupFlight('chain-autorefuel.db');
 
-    // Depart with exactly the wind-adjusted fuel for EDDF→LEMD (v0.36.0) → lands empty, cannot start LEMD→EHAM.
+    // Depart with exactly the wind-adjusted fuel for EDDF→LEMD (v0.36.0) → lands empty; the LEMD→EHAM hop needs a top-up.
     const w = weatherFor(FROM);
     const f = windBurnFactor(w.windKt, w.windDirDeg, initialBearingDeg(from.lat, from.lon, to.lat, to.lon));
+    const depFuel = requiredFuelFor(type.burnPerKm * f, type.emptyWeightKg, type.maxFuel, km);
     await inst.db.update(schema.planes)
-      .set({
+      .set({ fuel: depFuel, queue: JSON.stringify(['EHAM']) })
-        fuel: requiredFuelFor(type.burnPerKm * f, type.emptyWeightKg, type.maxFuel, km),
-        queue: JSON.stringify(['EHAM']),
-      })
       .where(eq(schema.planes.id, 'plane-starter'));
 
+    const accountBefore = (await inst.db.select().from(schema.account))[0]!; // seeded €20k — the top-up is affordable
+    const clock = T0 + travelMs(km, type.speedKmh); // exactly at arrival
+    expect(await deliverPackages(inst, clock)).toBe(1);
+
+    // Expected top-up from the SAME helpers the engine uses: landed fuel (≈ 0), post-wear health,
+    // wind-adjusted requirement for LEMD→EHAM, ×1.5 margin capped at tank capacity.
+    const fc = await loadAirportsGeoJson();
+    const nextP = fc.features.find((x) => x.properties.icao === 'EHAM')!.properties;
+    const landedFuel = fuelAtWeighted(depFuel, type.burnPerKm * f, type.emptyWeightKg, type.maxFuel, km, 1);
+    expect(landedFuel).toBeCloseTo(0, 6); // sanity: arrived empty — the top-up path is what ran
+    const newHealth = Math.max(0, 100 - WEAR_PER_KM * km);
+    const wTo = weatherFor(TO); // the chained leg departs from the arrival airport
+    const fNext = windBurnFactor(wTo.windKt, wTo.windDirDeg, initialBearingDeg(to.lat, to.lon, nextP.lat, nextP.lon));
+    const nextRequiredL = requiredFuelFor(
+      type.burnPerKm * fNext * conditionBurnMultiplier(newHealth),
+      type.emptyWeightKg,
+      type.maxFuel,
+      haversineKm(to.lat, to.lon, nextP.lat, nextP.lon),
+    );
+    const target = Math.min(type.maxFuel, Math.max(landedFuel, nextRequiredL * 1.5));
+    const liters = Math.max(0, target - landedFuel);
+    expect(liters).toBeGreaterThan(0); // the hop genuinely needs more than what's left
+    const rate = repRate(accountBefore.reputation, FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT);
+    const expectedCost = Math.round(liters * FUEL_PRICE_PER_L * (1 - rate) * 100) / 100;
+
+    const plane = (await inst.db.select().from(schema.planes))[0];
+    expect(plane.status).toBe('flying'); // chained — the top-up funded it…
+    expect(plane.destIcao).toBe('EHAM');
+    expect(plane.departureSimTime).toBe(clock);
+    expect(JSON.parse(plane.queue)).toEqual([]); // …leg consumed, rest kept in order
+    expect(plane.fuel).toBeCloseTo(target, 6); // …departing with the post-top-up level
+
+    const account = (await inst.db.select().from(schema.account))[0]!;
+    expect(account.cash).toBeCloseTo(accountBefore.cash - expectedCost, 9); // exactly the rep-discounted cost
+  });
+
+  it('grounds with the queue intact when cash cannot cover the auto top-up (ISS-082)', async () => {
+    const { inst, from, to, km, type } = await setupFlight('chain-nofuel-poor.db');
+
+    // Same empty-tank landing as above, but the account is broke — the top-up is unaffordable.
+    const w = weatherFor(FROM);
+    const f = windBurnFactor(w.windKt, w.windDirDeg, initialBearingDeg(from.lat, from.lon, to.lat, to.lon));
+    const depFuel = requiredFuelFor(type.burnPerKm * f, type.emptyWeightKg, type.maxFuel, km);
+    await inst.db.update(schema.planes)
+      .set({ fuel: depFuel, queue: JSON.stringify(['EHAM']) })
+      .where(eq(schema.planes.id, 'plane-starter'));
+    await inst.db.update(schema.account).set({ cash: 0 });
+
     const clock = T0 + travelMs(km, type.speedKmh); // exactly at arrival
     expect(await deliverPackages(inst, clock)).toBe(1);
 
@@ -317,7 +364,10 @@ describe('deliverPackages (v0.12.0 arrival delivery)', () => {
     expect(plane.status).toBe('available'); // grounded safely…
     expect(plane.destIcao).toBeNull();
     expect(plane.departureSimTime).toBeNull();
-    expect(JSON.parse(plane.queue)).toEqual(['EHAM']); // …queue kept for refuel + re-dispatch
+    expect(JSON.parse(plane.queue)).toEqual(['EHAM']); // …queue kept for a later dispatch
+    const landedFuel = fuelAtWeighted(depFuel, type.burnPerKm * f, type.emptyWeightKg, type.maxFuel, km, 1);
+    expect(plane.fuel).toBeCloseTo(landedFuel, 6); // no top-up happened — the tank is untouched
+    expect((await inst.db.select().from(schema.account))[0]!.cash).toBe(0);
   });
 
   it('grounds as before when the queue is empty', async () => {
@@ -331,6 +381,114 @@ describe('deliverPackages (v0.12.0 arrival delivery)', () => {
   });
 });
 
+describe('wear on landed legs + broken burn (v0.39.0, ISS-069)', () => {
+  const FROM = 'EDDF';
+  const TO = 'LEMD';
+
+  // Starter flying EDDF→LEMD with a full tank — same shape as the deliverPackages setup above.
+  async function setupFlight(name: string) {
+    const inst = await freshDb(name);
+    const fc = await loadAirportsGeoJson();
+    const from = fc.features.find((f) => f.properties.icao === FROM)!.properties;
+    const to = fc.features.find((f) => f.properties.icao === TO)!.properties;
+    const km = haversineKm(from.lat, from.lon, to.lat, to.lon);
+    const type = PLANE_TYPES.atr72;
+
+    await inst.db.update(schema.planes)
+      .set({ status: 'flying', destIcao: TO, departureSimTime: T0, fuel: type.maxFuel })
+      .where(eq(schema.planes.id, 'plane-starter'));
+
+    return { inst, from, to, km, type };
+  }
+
+  it('drops health by exactly WEAR_PER_KM × km on a landed leg', async () => {
+    const { inst, km } = await setupFlight('wear-leg.db');
+
+    expect(await deliverPackages(inst, T0 + travelMs(km, PLANE_TYPES.atr72.speedKmh))).toBe(1);
+
+    const plane = (await inst.db.select().from(schema.planes))[0];
+    expect(plane.health).toBeCloseTo(100 - WEAR_PER_KM * km, 9); // one mid-range hop ≈ −9.8 health
+  });
+
+  it('clamps at 0 across multiple legs', async () => {
+    const { inst, from, to, km, type } = await setupFlight('wear-clamp.db');
+    // Start below one leg's wear so the first landing clamps…
+    await inst.db.update(schema.planes)
+      .set({ health: WEAR_PER_KM * km / 2 })
+      .where(eq(schema.planes.id, 'plane-starter'));
+
+    expect(await deliverPackages(inst, T0 + travelMs(km, type.speedKmh))).toBe(1);
+    let plane = (await inst.db.select().from(schema.planes))[0];
+    expect(plane.health).toBe(0); // clamped — never negative…
+
+    // …and a second leg keeps it pinned at 0.
+    const eham = (await loadAirportsGeoJson()).features.find((f) => f.properties.icao === 'EHAM')!.properties;
+    const nextKm = haversineKm(to.lat, to.lon, eham.lat, eham.lon);
+    await inst.db.update(schema.planes)
+      .set({ status: 'flying', destIcao: 'EHAM', departureSimTime: T0 + travelMs(km, type.speedKmh), fuel: type.maxFuel })
+      .where(eq(schema.planes.id, 'plane-starter'));
+
+    expect(await deliverPackages(inst, T0 + travelMs(km, type.speedKmh) + travelMs(nextKm, type.speedKmh))).toBe(1);
+    plane = (await inst.db.select().from(schema.planes))[0];
+    expect(plane.health).toBe(0); // still clamped after the second leg
+  });
+
+  it('a broken plane burns ×1.5 more fuel on the leg (landed fuel)', async () => {
+    const { inst, from, to, km, type } = await setupFlight('wear-broken.db');
+    await inst.db.update(schema.planes).set({ health: 0 }).where(eq(schema.planes.id, 'plane-starter'));
+
+    expect(await deliverPackages(inst, T0 + travelMs(km, type.speedKmh))).toBe(1);
+
+    const w = weatherFor(FROM);
+    const f = windBurnFactor(w.windKt, w.windDirDeg, initialBearingDeg(from.lat, from.lon, to.lat, to.lon));
+    const plane = (await inst.db.select().from(schema.planes))[0];
+    // The ×1.5-adjusted closed form — the same factor livePlane() shows in flight…
+    expect(plane.fuel).toBeCloseTo(
+      fuelAtWeighted(type.maxFuel, type.burnPerKm * f * BROKEN_BURN_MULTIPLIER, type.emptyWeightKg, type.maxFuel, km, 1),
+      6,
+    );
+
+    // …and strictly less than the healthy control on the identical leg.
+    const control = await setupFlight('wear-broken-control.db');
+    expect(await deliverPackages(control.inst, T0 + travelMs(km, type.speedKmh))).toBe(1);
+    const healthy = (await control.inst.db.select().from(schema.planes))[0];
+    expect(healthy.fuel).toBeCloseTo(fuelAtWeighted(type.maxFuel, type.burnPerKm * f, type.emptyWeightKg, type.maxFuel, km, 1), 6);
+    expect(plane.fuel).toBeLessThan(healthy.fuel); // the broken plane genuinely burned more
+  });
+});
+
+describe('finishRepairs (v0.39.0, ISS-069)', () => {
+  it('flips repairing planes back to available once the gate passes, clearing the gate', async () => {
+    const inst = await freshDb('repair-finish.db');
+    await inst.db.update(schema.planes)
+      .set({ status: 'repairing', repairUntilSimTime: T0 + 5_000 })
+      .where(eq(schema.planes.id, 'plane-starter'));
+
+    expect(await finishRepairs(inst, T0 + 4_999)).toBe(0); // gate not reached yet…
+    let plane = (await inst.db.select().from(schema.planes))[0];
+    expect(plane.status).toBe('repairing');
+
+    expect(await finishRepairs(inst, T0 + 5_000)).toBe(1); // <= is inclusive at the clock
+    plane = (await inst.db.select().from(schema.planes))[0];
+    expect(plane.status).toBe('available');
+    expect(plane.repairUntilSimTime ?? null).toBeNull(); // gate cleared
+  });
+
+  it('runs inside tickOnce even when nothing landed: a past gate flips the plane back', async () => {
+    const inst = await freshDb('repair-tick.db');
+    await inst.db.update(schema.planes)
+      .set({ status: 'repairing', repairUntilSimTime: T0 + 1_500 })
+      .where(eq(schema.planes.id, 'plane-starter'));
+
+    vi.setSystemTime(T0 + 2_000); // one clamped tick at scale 1 → clock T0+2000 ≥ gate; nothing is flying
+    await tickOnce(inst);
+
+    const plane = (await inst.db.select().from(schema.planes))[0];
+    expect(plane.status).toBe('available');
+    expect(plane.repairUntilSimTime ?? null).toBeNull();
+  });
+});
+
 describe('slow to 1× when a landing leaves any plane on the ground (ISS-057)', () => {
   const FROM = 'EDDF';
   const TO = 'LEMD';

lib/sim/engine.ts

@@ -5,7 +5,7 @@ import * as schema from '@/lib/db/schema';
 import { loadAirportsGeoJson } from '@/lib/airports';
 import { haversineKm, initialBearingDeg } from '@/lib/geo';
 import { weatherFor } from '@/lib/weather';
-import { PLANE_TYPES } from '@/lib/game/catalog';
+import { conditionBurnMultiplier, FUEL_DISCOUNT_PER_REP, FUEL_PRICE_PER_L, MAX_FUEL_DISCOUNT, PLANE_TYPES, repRate, WEAR_PER_KM } from '@/lib/game/catalog';
 import { SPECIALS } from '@/lib/game/specials';
 import { parseIcaoQueue } from '@/lib/game/state';
 import {
@@ -79,6 +79,9 @@ export async function tickOnce(inst: GameDb): Promise<schema.SimStateRow> {
     await expirePackages(inst, clockMs);
     // ISS-057: remember the landings so the tick can slow down when a plane is left on ground.
     landedThisTick = await deliverPackages(inst, clockMs);
+    // v0.39.0 (ISS-069): repairs whose gate has passed flip back to 'available' — runs even when
+    // nothing landed this tick; BEFORE the spawns so a just-repaired plane gets coverage work too.
+    await finishRepairs(inst, clockMs);
     await spawnOpenPackages(inst, clockMs);
     // AFTER delivery on purpose: a plane that just landed gets work spawned
     // at its new location within the same tick.
@@ -126,14 +129,33 @@ export async function expirePackages(inst: GameDb, clockMs: number): Promise<num
   return n;
 }
 
+// Repairs whose gate has passed flip the plane back to 'available' and clear the gate
+// (v0.39.0, ISS-069) — same shape as expirePackages: one guarded pass over the rows,
+// `<=` inclusive at the clock. Returns the count flipped.
+export async function finishRepairs(inst: GameDb, clockMs: number): Promise<number> {
+  const rows = await inst.db.select().from(schema.planes).where(eq(schema.planes.status, 'repairing'));
+  let n = 0;
+  for (const p of rows) {
+    if (p.repairUntilSimTime !== null && p.repairUntilSimTime <= clockMs) {
+      await inst.db.update(schema.planes)
+        .set({ status: 'available', repairUntilSimTime: null })
+        .where(eq(schema.planes.id, p.id));
+      n++;
+    }
+  }
+  return n;
+}
+
 // Finalize in-flight planes whose arrival time has passed (v0.12.0 delivery):
 // for every package bound to the plane and destined for its dest_icao — 'loaded'
 // ones still inside their deadline are delivered (cash += reward + reputation
 // gain per package), 'expired' ones just unbind (no reward). Packages destined
 // elsewhere stay loaded on the plane for a later leg. Then (v0.25.0, ISS-043)
 // auto-chain: if the queue holds legs and fuel covers the first one, start it
-// immediately from the arrival airport; otherwise ground the plane there with
+// immediately from the arrival airport; with a short tank, ISS-082 (v0.42.0) tops
-// its remaining fuel (a short tank keeps the queue intact for refuel + re-dispatch).
+// up to 150% of the requirement (capped at tank capacity) when cash allows and
+// chains anyway — only an unaffordable top-up grounds the plane there with its
+// remaining fuel and the queue kept intact for a later dispatch.
 // Idempotent — a finalized plane either leaves the 'flying' state or starts a NEW
 // leg whose own arrival is in the future, so it can never be awarded twice.
 // Returns planes landed. NOTE: runs BEFORE tickOnce's slow-down check on purpose —
@@ -160,16 +182,21 @@ export async function deliverPackages(inst: GameDb, clockMs: number): Promise<nu
 
     // Arrived: progress is exactly 1 here, so remaining fuel is the full-leg weighted burn —
     // wind-adjusted (v0.36.0) by departure weather vs route heading, same factor flyPlane used.
+    // v0.39.0 (ISS-069): broken planes (health ≤ 0 at DEPARTURE) burn BROKEN_BURN_MULTIPLIER × more —
+    // p.health is the pre-landing value, so this stays bit-consistent with livePlane()'s gauge.
     const w = weatherFor(p.locationIcao);
     const landedFuel = fuelAtWeighted(
       p.fuel,
-      type.burnPerKm * windBurnFactor(w.windKt, w.windDirDeg, initialBearingDeg(from.lat, from.lon, to.lat, to.lon)),
+      type.burnPerKm * windBurnFactor(w.windKt, w.windDirDeg, initialBearingDeg(from.lat, from.lon, to.lat, to.lon)) * conditionBurnMultiplier(p.health),
       type.emptyWeightKg,
       type.maxFuel,
       distanceKm,
       1,
     );
 
+    // Wear (v0.39.0, ISS-069): health drops by WEAR_PER_KM per km of this landed leg, clamped at 0.
+    const newHealth = Math.max(0, p.health - WEAR_PER_KM * distanceKm);
+
     // Deliver every bound package whose destination is the airport just reached —
     // runs whether or not a queued leg chains next (ISS-043).
     const onBoard = packageRows.filter((pk) => pk.planeId === p.id && pk.destIcao === to.icao);
@@ -194,19 +221,23 @@ export async function deliverPackages(inst: GameDb, clockMs: number): Promise<nu
 
     // Auto-chain (ISS-043): with a non-empty queue and enough fuel for the first
     // queued leg, start it immediately from `to` — same feasibility rule as flyPlane
-    // (requiredFuelFor is independent of current load). Otherwise ground here; an
+    // (requiredFuelFor is independent of current load). ISS-082 (v0.42.0): manual refuel is gone,
-    // unknown ICAO in the queue simply cannot chain. The remaining queue is kept
+    // so a short tank no longer strands the chain — when cash allows, top up to 150% of the
-    // intact either way so a grounded plane can refuel and re-dispatch.
+    // requirement (capped at tank capacity) and chain anyway; unaffordable → ground here with the
+    // queue kept intact. An unknown ICAO in the queue simply cannot chain either way.
     const queue = parseIcaoQueue(p.queue);
     let chainedTo: string | null = null;
+    let topUpFuel: number | null = null; // post-top-up fuel for the chained departure, when a top-up happened
     if (queue.length > 0) {
       const nextDest = queue[0];
       const next = byIcao.get(nextDest); // unknown ICAO in the queue → cannot chain
       if (next) {
-        // Wind-adjusted requirement for the NEXT leg — it departs from `to` (v0.36.0).
+        // Wind-adjusted requirement for the NEXT leg — it departs from `to` (v0.36.0). v0.39.0 (ISS-069):
+        // the chained leg starts AFTER this landing's wear, so its burn uses newHealth — exactly what
+        // livePlane()/the next landing will compute for that flight.
         const wNext = weatherFor(to.icao);
         const nextRequiredL = requiredFuelFor(
-          type.burnPerKm * windBurnFactor(wNext.windKt, wNext.windDirDeg, initialBearingDeg(to.lat, to.lon, next.lat, next.lon)),
+          type.burnPerKm * windBurnFactor(wNext.windKt, wNext.windDirDeg, initialBearingDeg(to.lat, to.lon, next.lat, next.lon)) * conditionBurnMultiplier(newHealth),
           type.emptyWeightKg,
           type.maxFuel,
           haversineKm(to.lat, to.lon, next.lat, next.lon),
@@ -214,6 +245,20 @@ export async function deliverPackages(inst: GameDb, clockMs: number): Promise<nu
         if (nextRequiredL <= landedFuel) {
           queue.shift();
           chainedTo = nextDest;
+        } else {
+          // ISS-082: auto top-up — same target/price terms as flyPlane's dispatch refuel.
+          const target = Math.min(type.maxFuel, Math.max(landedFuel, nextRequiredL * 1.5));
+          const liters = Math.max(0, target - landedFuel);
+          // Fresh account read (same pattern as the delivery awards above) so a top-up in this tick sees current cash.
+          const fresh = (await inst.db.select().from(schema.account))[0];
+          if (!fresh) throw new Error('account row missing');
+          const cost = Math.round(liters * FUEL_PRICE_PER_L * (1 - repRate(fresh.reputation, FUEL_DISCOUNT_PER_REP, MAX_FUEL_DISCOUNT)) * 100) / 100;
+          if (cost === 0 || fresh.cash >= cost) {
+            queue.shift();
+            chainedTo = nextDest;
+            topUpFuel = target;
+            if (cost > 0) await inst.db.update(schema.account).set({ cash: Math.round((fresh.cash - cost) * 100) / 100 });
+          }
         }
       }
     }
@@ -225,7 +270,8 @@ export async function deliverPackages(inst: GameDb, clockMs: number): Promise<nu
               locationIcao: to.icao,
               lat: to.lat,
               lon: to.lon,
-              fuel: landedFuel,
+              fuel: topUpFuel ?? landedFuel, // ISS-082: the post-top-up level when a top-up funded the chain
+              health: newHealth, // v0.39.0 (ISS-069) — this leg's wear persists into the chained flight
               destIcao: chainedTo,
               departureSimTime: clockMs, // the arrival instant — position is exactly `to`
               queue: JSON.stringify(queue),
@@ -236,6 +282,7 @@ export async function deliverPackages(inst: GameDb, clockMs: number): Promise<nu
               lat: to.lat,
               lon: to.lon,
               fuel: landedFuel,
+              health: newHealth, // v0.39.0 (ISS-069) — this leg's wear persists on the grounded plane
               departureSimTime: null,
               destIcao: null,
               queue: JSON.stringify(queue),

package.json

@@ -1,6 +1,6 @@
 {
   "name": "flight-ops",
-  "version": "0.38.0",
+  "version": "0.42.0",
   "private": true,
   "scripts": {
     "dev": "next dev -p 3000",