feat(catalog): reload manifest overlay when a refreshed catalog changes

load_manifests() only ran at startup, so a manifest published via the
signed catalog sat dormant until the next service restart (found while
shipping the strfry manifest fixes: package.check-updates refreshed the
cache but the orchestrator kept rendering the old overlay).

- refresh_catalog now reports whether the cached bytes actually changed
  (write_cache skips identical rewrites), so unchanged hourly polls
  don't churn the manifest map.
- New ContainerOrchestrator::reload_manifests (default no-op); prod
  delegates to load_manifests — the rebuild is atomic under the state
  write lock, and the reconciler's durable user-stopped/uninstalled
  marker filters make a mid-session reload equivalent to the restart
  path that already runs on every boot.
- package.check-updates reloads on change and reports catalog_changed +
  manifests_reloaded; the hourly update-scheduler tick (and its startup
  refresh) do the same.

Tests: app_catalog 5/5 (new write_cache changed-detection test),
reconcile 16/16, knows_app 1/1.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>

core/archipelago/src/api/rpc/package/update.rs

@@ -172,18 +172,36 @@ impl RpcHandler {
 
     /// Manual "check for updates": refresh the remote app catalog now. The
     /// package scanner recomputes each app's `available-update` from the fresh
-    /// catalog on its next cycle and pushes it to the UI. Best-effort — a fetch
-    /// failure leaves the cached catalog in place and reports `refreshed: false`.
+    /// catalog on its next cycle and pushes it to the UI. When the catalog
+    /// bytes changed, the orchestrator's manifest overlay is reloaded in the
+    /// same call so catalog-shipped manifest fixes apply without a service
+    /// restart. Best-effort — a fetch failure leaves the cached catalog in
+    /// place and reports `refreshed: false`.
     pub(in crate::api::rpc) async fn handle_package_check_updates(
         &self,
         _params: Option<serde_json::Value>,
     ) -> Result<serde_json::Value> {
         match crate::container::app_catalog::refresh_catalog(&self.config.data_dir).await {
-            Ok(count) => Ok(serde_json::json!({
-                "status": "ok",
-                "refreshed": true,
-                "catalog_apps": count,
-            })),
+            Ok(refresh) => {
+                let mut manifests_reloaded = serde_json::Value::Null;
+                if refresh.changed {
+                    if let Some(orch) = &self.orchestrator {
+                        match orch.reload_manifests().await {
+                            Ok(n) => manifests_reloaded = serde_json::json!(n),
+                            Err(e) => tracing::warn!(
+                                "check-updates: manifest reload after catalog change failed: {e}"
+                            ),
+                        }
+                    }
+                }
+                Ok(serde_json::json!({
+                    "status": "ok",
+                    "refreshed": true,
+                    "catalog_apps": refresh.apps,
+                    "catalog_changed": refresh.changed,
+                    "manifests_reloaded": manifests_reloaded,
+                }))
+            }
             Err(e) => Ok(serde_json::json!({
                 "status": "ok",
                 "refreshed": false,

core/archipelago/src/container/app_catalog.rs

@@ -339,18 +339,31 @@ fn catalog_urls_from_mirrors(mirrors: &[crate::update::UpdateMirror]) -> Vec<Str
     urls
 }
 
+/// Outcome of [`refresh_catalog`]: the app count of the fetched catalog and
+/// whether the cached bytes actually changed. `changed` drives the manifest-
+/// overlay reload — catalog manifests only take effect once `load_manifests`
+/// re-runs, and reloading on every unchanged hourly poll would be pure churn.
+#[derive(Debug, Clone, Copy)]
+pub struct CatalogRefresh {
+    pub apps: usize,
+    pub changed: bool,
+}
+
 /// Fetch the catalog from the first reachable mirror and atomically write it to
-/// `<data_dir>/app-catalog.json`. Returns the number of apps in the catalog on
-/// success. Best-effort: a fetch failure leaves the existing cache untouched
+/// `<data_dir>/app-catalog.json`. Returns the app count and whether the cache
+/// changed. Best-effort: a fetch failure leaves the existing cache untouched
 /// (origin-always-wins; updates simply aren't refreshed this cycle).
-pub async fn refresh_catalog(data_dir: &Path) -> anyhow::Result<usize> {
+pub async fn refresh_catalog(data_dir: &Path) -> anyhow::Result<CatalogRefresh> {
     let mirrors = crate::update::load_mirrors(data_dir)
         .await
         .unwrap_or_default();
     let urls = catalog_urls_from_mirrors(&mirrors);
     if urls.is_empty() {
         debug!("app-catalog: no mirror-derived URLs to fetch from");
-        return Ok(0);
+        return Ok(CatalogRefresh {
+            apps: 0,
+            changed: false,
+        });
     }
 
     let client = reqwest::Client::builder()
@@ -362,11 +375,21 @@ pub async fn refresh_catalog(data_dir: &Path) -> anyhow::Result<usize> {
         match fetch_one(&client, url).await {
             Ok(catalog) => {
                 let count = catalog.apps.len();
-                write_cache(data_dir, &catalog)?;
-                // Invalidate the in-process cache so the next read re-parses.
-                *CACHE.lock().unwrap() = None;
-                info!("app-catalog: refreshed from {} ({} apps)", url, count);
-                return Ok(count);
+                let changed = write_cache(data_dir, &catalog)?;
+                if changed {
+                    // Invalidate the in-process cache so the next read re-parses.
+                    *CACHE.lock().unwrap() = None;
+                }
+                info!(
+                    "app-catalog: refreshed from {} ({} apps{})",
+                    url,
+                    count,
+                    if changed { ", changed" } else { ", unchanged" }
+                );
+                return Ok(CatalogRefresh {
+                    apps: count,
+                    changed,
+                });
             }
             Err(e) => {
                 debug!("app-catalog: fetch {} failed: {}", url, e);
@@ -419,13 +442,22 @@ async fn fetch_one(client: &reqwest::Client, url: &str) -> anyhow::Result<AppCat
     Ok(catalog)
 }
 
-fn write_cache(data_dir: &Path, catalog: &AppCatalog) -> anyhow::Result<()> {
+/// Atomically write the catalog cache. Returns `false` (skipping the write)
+/// when the serialized bytes are identical to what's already cached, so
+/// callers can tell a genuine catalog change from an unchanged poll.
+fn write_cache(data_dir: &Path, catalog: &AppCatalog) -> anyhow::Result<bool> {
     let dest = data_dir.join(APP_CATALOG_FILE);
-    let tmp = data_dir.join(format!("{}.tmp", APP_CATALOG_FILE));
     let json = serde_json::to_string_pretty(catalog)?;
+    if std::fs::read_to_string(&dest)
+        .map(|current| current == json)
+        .unwrap_or(false)
+    {
+        return Ok(false);
+    }
+    let tmp = data_dir.join(format!("{}.tmp", APP_CATALOG_FILE));
     std::fs::write(&tmp, json)?;
     std::fs::rename(&tmp, &dest)?;
-    Ok(())
+    Ok(true)
 }
 
 #[cfg(test)]
@@ -462,6 +494,31 @@ mod tests {
         assert_eq!(e.digest.as_deref(), Some("blake3:deadbeef"));
     }
 
+    #[test]
+    fn write_cache_reports_changed_only_on_new_bytes() {
+        // The changed flag gates the runtime manifest-overlay reload: an
+        // unchanged hourly poll must NOT report changed (or every tick would
+        // rebuild the manifest map), while a genuinely new catalog must.
+        let dir = tempfile::tempdir().unwrap();
+        let cat: AppCatalog = serde_json::from_str(
+            r#"{"schema":1,"apps":{"demo":{"version":"1.0.0"}}}"#,
+        )
+        .unwrap();
+        assert!(write_cache(dir.path(), &cat).unwrap(), "first write is a change");
+        assert!(
+            !write_cache(dir.path(), &cat).unwrap(),
+            "identical rewrite is not a change"
+        );
+        let cat2: AppCatalog = serde_json::from_str(
+            r#"{"schema":1,"apps":{"demo":{"version":"1.0.1"}}}"#,
+        )
+        .unwrap();
+        assert!(
+            write_cache(dir.path(), &cat2).unwrap(),
+            "new catalog bytes are a change"
+        );
+    }
+
     #[test]
     fn entry_carries_embedded_manifest() {
         let json = r#"{

core/archipelago/src/container/prod_orchestrator.rs

@@ -3614,6 +3614,14 @@ impl ContainerOrchestrator for ProdContainerOrchestrator {
         self.state.read().await.manifests.contains_key(app_id)
     }
 
+    async fn reload_manifests(&self) -> Result<usize> {
+        // Safe mid-session: the rebuild is atomic under the state write lock,
+        // and although it wipes the in-memory `disabled` set, reconcile also
+        // filters on the durable user-stopped/user-uninstalled markers — the
+        // same contract every service restart already relies on.
+        self.load_manifests().await
+    }
+
     async fn install(&self, app_id: &str) -> Result<String> {
         {
             let mut state = self.state.write().await;

core/archipelago/src/container/traits.rs

@@ -35,6 +35,16 @@ pub trait ContainerOrchestrator: Send + Sync {
         false
     }
 
+    /// Rebuild the in-memory manifest map (disk + signed-catalog overlay).
+    /// Called after a runtime catalog refresh detects changed bytes so catalog
+    /// manifest changes take effect without a service restart — without this,
+    /// `load_manifests` only runs at startup and a freshly published manifest
+    /// sits dormant until the next restart. Returns the merged manifest count.
+    /// Defaults to a no-op for orchestrators without a manifest registry.
+    async fn reload_manifests(&self) -> Result<usize> {
+        Ok(0)
+    }
+
     /// Start an already-created container.
     async fn start(&self, app_id: &str) -> Result<()>;
 

core/archipelago/src/main.rs

@@ -222,7 +222,10 @@ async fn main() -> Result<()> {
         )
         .await
         {
-            Ok(Ok(n)) => info!("🛰️  app-catalog refreshed before manifest load ({n} apps)"),
+            Ok(Ok(r)) => info!(
+                "🛰️  app-catalog refreshed before manifest load ({} apps)",
+                r.apps
+            ),
             Ok(Err(e)) => tracing::debug!("app-catalog pre-load refresh failed (using cache): {e}"),
             Err(_) => tracing::debug!("app-catalog pre-load refresh timed out (using cache)"),
         }

core/archipelago/src/update.rs

@@ -1897,6 +1897,23 @@ async fn apply_per_app_auto_updates(
     }
 }
 
+/// After a catalog refresh that changed the cached bytes, rebuild the
+/// orchestrator's manifest map so registry-shipped manifest changes take
+/// effect now instead of at the next service restart.
+async fn reload_manifests_if_changed(
+    refresh: crate::container::app_catalog::CatalogRefresh,
+    orchestrator: &Option<std::sync::Arc<dyn crate::container::traits::ContainerOrchestrator>>,
+) {
+    if !refresh.changed {
+        return;
+    }
+    let Some(orch) = orchestrator else { return };
+    match orch.reload_manifests().await {
+        Ok(n) => info!("Update scheduler: catalog changed, reloaded {n} manifest(s)"),
+        Err(e) => warn!("Update scheduler: manifest reload after catalog change failed: {e}"),
+    }
+}
+
 pub async fn run_update_scheduler(
     data_dir: std::path::PathBuf,
     orchestrator: Option<std::sync::Arc<dyn crate::container::traits::ContainerOrchestrator>>,
@@ -1908,11 +1925,12 @@ pub async fn run_update_scheduler(
 
     // Refresh the app catalog once at startup so per-app "update available"
     // badges appear without waiting for the first hourly tick.
-    if let Err(e) = crate::container::app_catalog::refresh_catalog(&data_dir).await {
-        debug!(
+    match crate::container::app_catalog::refresh_catalog(&data_dir).await {
+        Ok(refresh) => reload_manifests_if_changed(refresh, &orchestrator).await,
+        Err(e) => debug!(
             "Update scheduler: initial app-catalog refresh failed: {}",
             e
-        );
+        ),
     }
 
     loop {
@@ -1922,8 +1940,11 @@ pub async fn run_update_scheduler(
         // populates per-app update availability (the "Update" button still has
         // to be clicked — nothing auto-applies). Best-effort; on failure the
         // previously cached catalog stays in place (origin-always-wins).
-        if let Err(e) = crate::container::app_catalog::refresh_catalog(&data_dir).await {
-            debug!("Update scheduler: app-catalog refresh failed: {}", e);
+        // A changed catalog also reloads the orchestrator's manifest overlay so
+        // catalog-shipped manifest fixes apply without a service restart.
+        match crate::container::app_catalog::refresh_catalog(&data_dir).await {
+            Ok(refresh) => reload_manifests_if_changed(refresh, &orchestrator).await,
+            Err(e) => debug!("Update scheduler: app-catalog refresh failed: {}", e),
         }
 
         // Per-app auto-update-to-latest (multi-version support). Runs every tick