Root cause: driveA33's A33.1 hard-gated on the chrome.runtime.sendMessage SAVE_ARCHIVE callback ack. After the Puppeteer CDP worker.close() SW kill, the SAVE_ARCHIVE message wakes a fresh SW instance; that instance runs the multi-step saveArchive() pipeline (offscreen video-keepalive port re-establishment + REQUEST_BUFFER round-trip + rrweb collection + zip build). The harness's original sendMessage response port has its own MV3 lifetime — on a 5-min-aged SW the pipeline INTERMITTENTLY outruns it, surfacing chrome.runtime.lastError "message port closed before a response was received". The archive is still written correctly every time, which is why A33.2/A33.3 always passed (Plan 04-05 full-mode UAT: A33.1 FAIL while A33.2/A33.3 PASS at 1.56 MB). A33.1 was gating a CI assertion on a best-effort transport ack with inherent MV3 non-determinism. Fix (harness-side only, Option A — race-free reframe): A33.1 now gates on the durable race-free signal — a fresh archive on disk — via the canonical snapshotExistingZips + pollForNewOrUpdatedZip helpers (also used by driveA12/A13/A27). The sendMessage ack is demoted to a soft non-gating diagnostic. This is exactly the signal the proven-reliable spike already uses. A33.2/A33.3 substantive checks are intact and now read the verified fresh zip. No new symbol; FORBIDDEN_HOOK_STRINGS unchanged at 12. The SW SAVE_ARCHIVE handler is a correct MV3 async pattern — no production change. Verified: full-mode A33 (genuine 5-min idle) 3/3 GREEN; skip-mode UAT 35/35 GREEN; tsc + build:test exit 0; vitest 184/184. Debug session: .planning/debug/a33-save-ack-race.md Co-Authored-By: Claude Opus 4.7 <noreply@anthropic.com>
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