fix: video size error handling — validation, timeouts, failure surfacing

Backend:
- Increase ffmpeg/ffprobe timeouts from 15s to 60s for large videos
- Classify processing errors (timeout, OOM, corrupt) with user-facing messages
- Emit failure details via media:job:update socket event (error field)
- Bump refboard container memory 512M → 1G

Frontend:
- Client-side file size validation (200MB) before upload starts
- Oversized files show immediate error in upload manager, skip upload
- Handle media:job:update status='failed' — surface error in upload panel
- Add processingFailed() to UploadManager for video processing errors

backend/services/media-worker.js

@@ -85,14 +85,14 @@ async function processJob(job) {
     const image = getImage(imageId);
     if (!image) {
       updateMediaJob(jobId, { status: 'failed', error: 'Image record not found' });
-      emitJobUpdate(boardId, jobId, imageId, 'failed');
+      emitJobFailed(boardId, jobId, imageId, 'Image record not found');
       return;
     }
 
     const videoBuffer = await fetchFromMinio(image.minio_path);
     if (!videoBuffer) {
       updateMediaJob(jobId, { status: 'failed', error: 'Failed to fetch video from storage' });
-      emitJobUpdate(boardId, jobId, imageId, 'failed');
+      emitJobFailed(boardId, jobId, imageId, 'Failed to fetch video from storage');
       return;
     }
 
@@ -131,13 +131,23 @@ async function processJob(job) {
   } catch (err) {
     console.error('[media-worker] Job %s failed:', jobId, err.message);
 
+    // Classify error for user-facing message
+    let userError = 'Video processing failed';
+    if (err.killed || err.signal === 'SIGTERM') {
+      userError = 'Video processing timed out — file may be too large or corrupt';
+    } else if (err.message?.includes('ENOMEM') || err.message?.includes('Cannot allocate')) {
+      userError = 'Out of memory — video file is too large to process';
+    } else if (err.message?.includes('Invalid data')) {
+      userError = 'Invalid or corrupt video file';
+    }
+
     const attempts = (job.attempts || 0) + 1;
     if (attempts < 3) {
       updateMediaJob(jobId, { status: 'retry', attempts, error: err.message });
       emitJobUpdate(boardId, jobId, imageId, 'retry');
     } else {
       updateMediaJob(jobId, { status: 'failed', attempts, error: err.message });
-      emitJobUpdate(boardId, jobId, imageId, 'failed');
+      emitJobFailed(boardId, jobId, imageId, userError);
     }
   }
 }
@@ -173,4 +183,11 @@ function emitJobUpdate(boardId, jobId, imageId, status, result) {
   });
 }
 
+/**
+ * Emit a job failure with error details to the board room.
+ */
+function emitJobFailed(boardId, jobId, imageId, error) {
+  emitJobUpdate(boardId, jobId, imageId, 'failed', { error });
+}
+
 module.exports = { startMediaWorker, stopMediaWorker };

backend/video-utils.js

@@ -34,7 +34,7 @@ function probeVideo(buffer) {
       '-show_format',
       '-show_streams',
       tmpFile,
-    ], { timeout: 15000 }, (err, stdout) => {
+    ], { timeout: 60000 }, (err, stdout) => {
       cleanup(tmpFile, tmpDir);
       if (err) {
         console.warn('[video-utils] ffprobe failed:', err.message);
@@ -91,7 +91,7 @@ function extractPoster(buffer) {
       '-q:v', '3',           // JPEG quality (2=best, 31=worst)
       '-y',                  // overwrite
       tmpOutput,
-    ], { timeout: 15000 }, (err) => {
+    ], { timeout: 60000 }, (err) => {
       if (err) {
         console.warn('[video-utils] ffmpeg poster extraction failed:', err.message);
         cleanup(tmpInput, tmpDir);

frontend/src/canvas/image-drop.ts

@@ -7,6 +7,10 @@ import { uploadImage, uploadImageFromUrl } from '../api';
 
 type OnChange = () => void;
 
+/** Client-side file size limit (matches backend MAX_FILE_SIZE_MB default) */
+const MAX_FILE_SIZE_MB = 200;
+const MAX_FILE_SIZE = MAX_FILE_SIZE_MB * 1024 * 1024;
+
 /* ------------------------------------------------------------------ */
 /*  Placeholder helper                                                 */
 /* ------------------------------------------------------------------ */
@@ -153,6 +157,15 @@ export function setupDragDrop(
       let cursorX = world.x;
       for (let c = 0; c < col; c++) cursorX += (colWidths[c] || 220) + GAP;
 
+      // Client-side size validation
+      if (file.size > MAX_FILE_SIZE) {
+        const jobId = uploads?.addJob(file, boardId);
+        if (jobId) uploads?.setFailed(jobId, `File too large (${(file.size / 1024 / 1024).toFixed(0)}MB, max ${MAX_FILE_SIZE_MB}MB)`);
+        col++;
+        if (col >= cols) { col = 0; row++; cursorY += rowMaxH + GAP; rowMaxH = 0; }
+        continue;
+      }
+
       const placeholder = createPlaceholder(viewport, cursorX, cursorY);
       const jobId = uploads?.addJob(file, boardId);
 
@@ -241,6 +254,13 @@ export function setupPaste(
       const file = item.getAsFile();
       if (!file) continue;
 
+      // Client-side size validation
+      if (file.size > MAX_FILE_SIZE) {
+        const jobId = uploads?.addJob(file, boardId);
+        if (jobId) uploads?.setFailed(jobId, `File too large (${(file.size / 1024 / 1024).toFixed(0)}MB, max ${MAX_FILE_SIZE_MB}MB)`);
+        continue;
+      }
+
       // Place at viewport center (world coords)
       const center = viewport.center;
       const cx = center.x;

frontend/src/hooks/useCanvasSetup.ts

@@ -184,10 +184,18 @@ export function useCanvasSetup(deps: CanvasSetupDeps) {
 
         // Media processing pipeline: upgrade videos when poster/metadata arrives
         socket.on('media:job:update', (data: any) => {
-          if (!data || data.status !== 'done') return;
+          if (!data) return;
-          const { imageId, posterAssetKey, nativeWidth, nativeHeight, duration } = data;
+          const { imageId, status } = data;
           if (!imageId) return;
 
+          // Surface processing failures to upload manager
+          if (status === 'failed') {
+            uploadManager.processingFailed(imageId, data.error || 'Video processing failed');
+            return;
+          }
+          if (status !== 'done') return;
+          const { posterAssetKey, nativeWidth, nativeHeight, duration } = data;
+
           // Update upload manager — transitions video jobs from "processing" to "done"
           uploadManager.processingComplete(imageId);
 

frontend/src/stores/uploadManager.ts

@@ -88,6 +88,18 @@ export class UploadManager {
     }
   }
 
+  /** Video processing failed (from media:job:update socket event with status='failed'). */
+  processingFailed(imageId: string, error: string) {
+    for (const job of this.jobs.values()) {
+      if (job.imageId === imageId && (job.status === 'processing' || job.status === 'uploading')) {
+        job.status = 'failed';
+        job.error = error;
+        this._notify();
+        return;
+      }
+    }
+  }
+
   /** Mark a job as failed. */
   setFailed(jobId: string, error: string) {
     const job = this.jobs.get(jobId);