feat(summarizer): resilient endpoint chain with local→cloud fallback (ADR-022)

The first friendly-pilot live run produced zero summaries: koala/phi4-mini hit
three silent failure modes — 8k context overflow on long transcripts (HTTP 400),
intermittent malformed JSON (highlights as a bare string), and no fallback wired
at all (summarizer.New(primary, nil)).

Keep phi4-mini as the fast primary and add resilience around it:

- Ordered endpoint chain (summarizer.NewChain): phi4-mini → koala/phi4-14b
  (local) → berget/mistral-small (worst-case external). All reached through the
  one LiteLLM gateway by alias.
- A parse failure now advances the chain like a transport error — the old
  Primary→Fallback shape returned the parse error without trying anyone else.
- Tolerant parse: highlights/takeaways coerce string→[]string, absorbing the
  common small-model quirk without spending a fallback round-trip.
- Transcript truncation (TAPIR_MAX_TRANSCRIPT_CHARS=18000) prevents the overflow
  rather than recovering from it; validated to fit phi4-mini's 8k window.
- Bounded completion budget (TAPIR_SUMMARY_MAX_TOKENS=1500) — the old 8192 budget
  itself contributed to the overflow.

Local-first guarantee preserved by ordering: external endpoint is tried only
after every local one fails. TAPIR_CLOUD_FALLBACK_MODEL="" disables it entirely
for client/NDA deployments.

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

internal/config/config.go

@@ -28,8 +28,24 @@ type Config struct {
 	GatewayURL string
 	// GatewayKey authorizes the gateway. Read from env, never committed.
 	GatewayKey string
-	// SummarizerModel is the alias in host/name form, e.g. "koala/phi4-mini".
+	// SummarizerModel is the primary summarizer alias in host/name form, tried
+	// first on every video, e.g. "koala/phi4-mini".
 	SummarizerModel string
+	// FallbackModel is the LOCAL fallback alias tried when the primary fails or
+	// returns unparseable output (ADR-022). Kept local so content stays on the
+	// homelab stack. Empty disables it. Default a bigger-context local model.
+	FallbackModel string
+	// CloudFallbackModel is the worst-case EXTERNAL fallback alias, tried only
+	// after every local endpoint has failed (ADR-022). For client deployments set
+	// this empty so content never leaves the local stack. Default a berget alias.
+	CloudFallbackModel string
+	// SummaryMaxTokens caps the completion budget per summary call. Small-context
+	// models (koala/phi4-mini, 8k) overflow when prompt + max_tokens exceeds the
+	// window; a summary needs only a few hundred tokens, so the default is small.
+	SummaryMaxTokens int
+	// MaxTranscriptChars bounds the transcript text sent to the model so a long
+	// transcript does not overflow a small-context primary. 0 disables truncation.
+	MaxTranscriptChars int
 	// SummarizerTimeout bounds a single completion call. Thinking models are
 	// slow, so the default is generous.
 	SummarizerTimeout time.Duration
@@ -118,6 +134,10 @@ func (c Config) DexConfigured() bool { return strings.TrimSpace(c.OIDCIssuer) !=
 const (
 	defaultGatewayURL            = "http://koala:30401/v1"
 	defaultSummarizerModel       = "koala/phi4-mini"
+	defaultFallbackModel         = "koala/phi4-14b"
+	defaultCloudFallbackModel    = "berget/mistral-small"
+	defaultSummaryMaxTokens      = 1500
+	defaultMaxTranscriptChars    = 18000
 	defaultSummarizerTimeout     = 5 * time.Minute
 	defaultYTTokenRef            = "youtube/refresh_token"
 	defaultYTConnectRedirectURL  = "https://tapir.d-ma.be/oauth/youtube/callback"
@@ -141,6 +161,8 @@ func Load() (Config, error) {
 		GatewayURL:           envOr("TAPIR_GATEWAY_URL", defaultGatewayURL),
 		GatewayKey:           os.Getenv("TAPIR_GATEWAY_KEY"),
 		SummarizerModel:      envOr("TAPIR_SUMMARIZER_MODEL", defaultSummarizerModel),
+		FallbackModel:        lookupOr("TAPIR_FALLBACK_MODEL", defaultFallbackModel),
+		CloudFallbackModel:   lookupOr("TAPIR_CLOUD_FALLBACK_MODEL", defaultCloudFallbackModel),
 		DBDSN:                os.Getenv("TAPIR_DB_DSN"),
 		YTClientID:           os.Getenv("TAPIR_YT_CLIENT_ID"),
 		YTClientSecret:       os.Getenv("TAPIR_YT_CLIENT_SECRET"),
@@ -193,6 +215,21 @@ func Load() (Config, error) {
 	}
 	c.AutoSummarizeWindow = autoWindow
 
+	summaryTokens, err := intOr("TAPIR_SUMMARY_MAX_TOKENS", defaultSummaryMaxTokens)
+	if err != nil {
+		return Config{}, err
+	}
+	c.SummaryMaxTokens = summaryTokens
+
+	maxChars, err := intOr("TAPIR_MAX_TRANSCRIPT_CHARS", defaultMaxTranscriptChars)
+	if err != nil {
+		return Config{}, err
+	}
+	if maxChars < 0 {
+		maxChars = 0
+	}
+	c.MaxTranscriptChars = maxChars
+
 	onboard, err := intOr("TAPIR_ONBOARD_SUMMARIZE_COUNT", defaultOnboardSummarizeCount)
 	if err != nil {
 		return Config{}, err
@@ -269,6 +306,17 @@ func envOr(key, fallback string) string {
 	return fallback
 }
 
+// lookupOr returns the env value when the key is PRESENT (even if empty), else
+// fallback. Unlike envOr it lets an explicit empty value override the default —
+// needed to DISABLE an optional fallback model (e.g. set the cloud fallback empty
+// for a client deployment so content never leaves the local stack).
+func lookupOr(key, fallback string) string {
+	if v, ok := os.LookupEnv(key); ok {
+		return v
+	}
+	return fallback
+}
+
 func intOr(key string, fallback int) (int, error) {
 	v := os.Getenv(key)
 	if v == "" {

internal/config/config_test.go

@@ -1,11 +1,29 @@
 package config
 
 import (
+	"os"
 	"strings"
 	"testing"
 	"time"
 )
 
+// unset removes an env key for the duration of the test, restoring it after.
+// Needed to observe a default for a key read with LookupEnv (where present-empty
+// means "explicitly disabled", not "use default").
+func unset(t *testing.T, key string) {
+	t.Helper()
+	if old, ok := os.LookupEnv(key); ok {
+		t.Cleanup(func() {
+			if err := os.Setenv(key, old); err != nil {
+				t.Fatalf("restore %s: %v", key, err)
+			}
+		})
+	}
+	if err := os.Unsetenv(key); err != nil {
+		t.Fatalf("unset %s: %v", key, err)
+	}
+}
+
 // setEnv sets env vars for the test and clears them afterward, so cases don't
 // leak into one another. t.Setenv handles restoration.
 func setEnv(t *testing.T, kv map[string]string) {
@@ -53,6 +71,46 @@ func TestLoad_AppliesDefaults(t *testing.T) {
 	}
 }
 
+func TestLoad_SummarizerChainDefaults(t *testing.T) {
+	setEnv(t, map[string]string{
+		"TAPIR_SUMMARIZER_MODEL":     "",
+		"TAPIR_SUMMARY_MAX_TOKENS":   "",
+		"TAPIR_MAX_TRANSCRIPT_CHARS": "",
+	})
+	unset(t, "TAPIR_FALLBACK_MODEL")
+	unset(t, "TAPIR_CLOUD_FALLBACK_MODEL")
+
+	c, err := Load()
+	if err != nil {
+		t.Fatalf("Load: %v", err)
+	}
+	if c.FallbackModel != defaultFallbackModel {
+		t.Errorf("FallbackModel = %q, want %q", c.FallbackModel, defaultFallbackModel)
+	}
+	if c.CloudFallbackModel != defaultCloudFallbackModel {
+		t.Errorf("CloudFallbackModel = %q, want %q", c.CloudFallbackModel, defaultCloudFallbackModel)
+	}
+	if c.SummaryMaxTokens != defaultSummaryMaxTokens {
+		t.Errorf("SummaryMaxTokens = %d, want %d", c.SummaryMaxTokens, defaultSummaryMaxTokens)
+	}
+	if c.MaxTranscriptChars != defaultMaxTranscriptChars {
+		t.Errorf("MaxTranscriptChars = %d, want %d", c.MaxTranscriptChars, defaultMaxTranscriptChars)
+	}
+}
+
+// An explicitly empty cloud-fallback env disables external routing — the lever a
+// client deployment pulls so content never leaves the local stack.
+func TestLoad_EmptyCloudFallbackDisables(t *testing.T) {
+	t.Setenv("TAPIR_CLOUD_FALLBACK_MODEL", "")
+	c, err := Load()
+	if err != nil {
+		t.Fatalf("Load: %v", err)
+	}
+	if c.CloudFallbackModel != "" {
+		t.Errorf("CloudFallbackModel = %q, want empty (disabled)", c.CloudFallbackModel)
+	}
+}
+
 func TestLoad_OnboardSummarizeCount(t *testing.T) {
 	cases := []struct {
 		name, env string