[ANDROIDHASSAN]

Problem: RecorderIO._encode_thread creates the output directory, opens the Ogg container and adds the Opus stream before its try. If any of those raise (an unwritable or misconfigured session directory, a codec that can't be added), the thread dies without reaching the finally that resolves _close_fut. RecorderIO.aclose() then waits on _close_fut forever, and so do AgentSession.aclose() and the job shutdown in job.py that awaits it.

A second problem compounds the first: once the encode thread has exited, nothing drains self._q, but on_frame and on_played keep queueing every input and played frame for the rest of the session, so the audio piles up in memory until the process ends.

Fix:

• Setup now runs inside the try, so a failure is logged by the existing handler and the finally still resolves _close_fut. The container is entered with with av.open(...) before the stream is added, so a failed add_stream still closes the file.
• All queue puts go through a new _put, which drops items once _close_fut is done, which is when the encode thread has exited. RecorderAudioOutput.capture_frame checks the same condition, so the agent side stops buffering segments too.
• start() creates a fresh queue, so audio left behind by a run whose encoder failed can't reach the next run's timeline.

Most of the source diff is re-indentation. git diff -w shows about 15 changed lines.

Tests

Three new cases in tests/test_recorder_io.py. Both point the recorder at a path whose parent is a regular file, so mkdir raises:

• test_a_failed_encoder_setup_does_not_hang_close: aclose() must return within 5 s. On main it times out, and pytest reports the encode thread's unhandled FileExistsError.
• test_a_failed_encoder_stops_buffering_audio: after the encode thread exits, ten more input frames must not grow the queue, and an agent frame must not open a segment buffer. On main this test errors, because the encode thread dies unhandled and aclose() never returns.
• test_a_restart_does_not_record_audio_left_over_from_a_failed_run: a frame left in a failed run's queue must not appear in the next run's file.

$ uv run pytest tests/test_recorder_io.py tests/test_recording.py tests/test_telemetry_recording_disabled.py -q
101 passed
$ uv run pytest --unit --audio_eot -q
4966 passed, 5 skipped

ruff format, ruff check and make type-check are clean.

Scope: only recorder_io.py. recording still reports True after a failure, so job.py still calls aclose(), which now returns. This PR does not change that behaviour. #7740 touches the codec setup lines in the same function. Whichever PR merges second needs a small rebase, and I'll do it.

🤖 Generated with Claude Code

[longcw]

lgtm!