fix: misc bug fixes and reliability improvements

- Fix `refreshCreditsJob` to treat `null` `lastFetchedAt` as needing refresh (not just missing cast entry)
- Fix `buildBackupCron` 6h expression to correctly fire every 6 hours using explicit hour list instead of `*/6`
- Fix `vacuumDatabase` to pass the path directly as a bound parameter (the manual escape was redundant and incorrect)
- Clean up orphaned `.tmp` files when image cache writes fail in both `downloadAndCacheImage` and `fetchAndMaybeCache`
- Surface import job payload parse/validation errors as job-level `error` status instead of throwing unhandled exceptions; check for cancellation before the processing loop starts
- Replace bare `Error` throws in `readImportJob` with `ORPCError` (`NOT_FOUND` / `FORBIDDEN`) so oRPC maps them to correct HTTP status codes
- Auto-promote title status to `in_progress` when `logEpisodeWatchBatch` is called for titles that have no status or are only on the watchlist
- Refresh seasons from TMDB when a webhook references a season not yet in the DB (handles newly-released seasons)
- Upgrade fire-and-forget enrichment failures and webhook processing errors from `log.debug` → `log.warn` so they surface in production logs

apps/server/src/cron.ts

@@ -218,7 +218,7 @@ async function refreshCreditsJob() {
   for (const titleId of libraryIds) {
     const castEntry = getCastEntryForTitle(titleId);
 
-    const needsRefresh = !castEntry || (castEntry.lastFetchedAt && castEntry.lastFetchedAt < stale);
+    const needsRefresh = !castEntry || !castEntry.lastFetchedAt || castEntry.lastFetchedAt < stale;
 
     if (needsRefresh) {
       await refreshCredits(titleId);
@@ -254,7 +254,7 @@ export function buildBackupCron(
 
   switch (frequency) {
     case "6h":
-      return `${m} */6 * * *`;
+      return `${m} ${h},${(h + 6) % 24},${(h + 12) % 24},${(h + 18) % 24} * * *`;
     case "12h":
       return `${m} ${h},${(h + 12) % 24} * * *`;
     case "7d":

apps/server/src/orpc/procedures/imports.ts

@@ -171,7 +171,7 @@ export const createJob = os.imports.createJob.use(authed).handler(async ({ input
     log.error(`Import job ${job.id} failed:`, err);
   });
 
-  return readImportJob(job.id);
+  return readImportJob(job.id, context.user.id);
 });
 
 export const getJob = os.imports.getJob.use(authed).handler(({ input, context }) => {
@@ -187,7 +187,7 @@ export const cancelJob = os.imports.cancelJob.use(authed).handler(({ input, cont
     });
   }
   updateImportJobProgress(input.id, { status: "cancelled" });
-  return readImportJob(input.id);
+  return readImportJob(input.id, context.user.id);
 });
 
 export const jobEvents = os.imports.jobEvents.use(authed).handler(async function* ({

apps/server/src/orpc/procedures/titles.ts

@@ -13,10 +13,13 @@ import {
   removeTitleStatus,
   setTitleStatus,
 } from "@sofa/core/tracking";
+import { createLogger } from "@sofa/logger";
 
 import { os } from "../context";
 import { authed } from "../middleware";
 
+const log = createLogger("titles");
+
 export const detail = os.titles.detail.use(authed).handler(async ({ input }) => {
   const result = await getOrFetchTitle(input.id);
   if (!result)
@@ -77,7 +80,9 @@ export const quickAdd = os.titles.quickAdd.use(authed).handler(async ({ input, c
   }
 
   // Trigger full TMDB import if still a shell (fire-and-forget)
-  getOrFetchTitleByTmdbId(result.tmdbId, result.type as "movie" | "tv").catch(() => {});
+  getOrFetchTitleByTmdbId(result.tmdbId, result.type as "movie" | "tv").catch((err) => {
+    log.warn(`Failed to import ${result.type} TMDB ${result.tmdbId}:`, err);
+  });
 
   return { id: result.id, alreadyAdded: result.alreadyAdded };
 });

apps/server/src/routes/webhooks.ts

@@ -53,7 +53,7 @@ app.post("/:token", async (c) => {
     await processWebhook(connection.id, connection.userId, provider, event);
   } catch (err) {
     // Swallow errors — never return non-200 to media servers
-    log.debug("Webhook processing failed:", err);
+    log.warn("Webhook processing failed:", err);
   }
 
   return c.json({ ok: true });

packages/core/src/image-cache.ts

@@ -1,4 +1,4 @@
-import { mkdir, rename } from "node:fs/promises";
+import { mkdir, rename, unlink } from "node:fs/promises";
 import path from "node:path";
 
 import { CACHE_DIR, TMDB_IMAGE_BASE_URL } from "@sofa/config";
@@ -101,6 +101,7 @@ export async function downloadAndCacheImage(
     log.debug(`Cached ${category}/${filename} (${buffer.length} bytes)`);
   } catch (err) {
     log.warn(`Failed to write cached image ${filename}:`, err);
+    unlink(tmpPath).catch(() => {});
   }
 
   return buffer;
@@ -132,7 +133,10 @@ export async function fetchAndMaybeCache(
   const tmpPath = `${finalPath}.tmp.${Date.now()}`;
   Bun.write(tmpPath, buffer)
     .then(() => rename(tmpPath, finalPath))
-    .catch((err) => log.warn(`Failed to cache ${category}/${filename}:`, err));
+    .catch((err) => {
+      log.warn(`Failed to cache ${category}/${filename}:`, err);
+      unlink(tmpPath).catch(() => {});
+    });
 
   return { buffer, contentType };
 }

packages/core/src/imports/processor.ts

@@ -1,3 +1,5 @@
+import { ORPCError } from "@orpc/server";
+
 import { type ImportJob, NormalizedImportSchema } from "@sofa/api/schemas";
 import {
   getImportJob,
@@ -254,11 +256,11 @@ export function readImportJob(jobId: string, userId?: string): ImportJob {
   const row = getImportJob(jobId);
 
   if (!row) {
-    throw new Error(`Import job ${jobId} not found`);
+    throw new ORPCError("NOT_FOUND", { message: `Import job ${jobId} not found` });
   }
 
   if (userId && row.userId !== userId) {
-    throw new Error("Not authorized");
+    throw new ORPCError("FORBIDDEN", { message: "Not authorized" });
   }
 
   return {
@@ -285,18 +287,33 @@ export async function processImportJob(jobId: string): Promise<void> {
   const row = getImportJob(jobId);
 
   if (!row) {
-    throw new Error(`Import job ${jobId} not found`);
+    log.error(`Import job ${jobId} not found`);
+    return;
   }
 
   let rawPayload: unknown;
   try {
     rawPayload = JSON.parse(row.payload);
   } catch {
-    throw new Error(`Import job ${jobId} has invalid JSON payload`);
+    updateImportJobProgress(jobId, {
+      status: "error",
+      finishedAt: new Date(),
+      errors: JSON.stringify([`Import job ${jobId} has invalid JSON payload`]),
+      currentMessage: "Import failed",
+    });
+    log.error(`Import job ${jobId} has invalid JSON payload`);
+    return;
   }
   const parsed = NormalizedImportSchema.safeParse(rawPayload);
   if (!parsed.success) {
-    throw new Error(`Import job ${jobId} has malformed payload: ${parsed.error.message}`);
+    updateImportJobProgress(jobId, {
+      status: "error",
+      finishedAt: new Date(),
+      errors: JSON.stringify([`Malformed payload: ${parsed.error.message}`]),
+      currentMessage: "Import failed",
+    });
+    log.error(`Import job ${jobId} has malformed payload: ${parsed.error.message}`);
+    return;
   }
   const data = parsed.data;
   const result: ImportResult = {
@@ -343,6 +360,18 @@ export async function processImportJob(jobId: string): Promise<void> {
       return;
     }
 
+    // Check if the job was cancelled while we were preparing
+    const preStartStatus = getImportJobStatus(jobId);
+    if (preStartStatus?.status === "cancelled") {
+      updateImportJobProgress(jobId, {
+        finishedAt: new Date(),
+        totalItems: total,
+        currentMessage: "Import cancelled",
+      });
+      log.info(`Import job ${jobId} was cancelled before processing started`);
+      return;
+    }
+
     // Set status to running + totalItems atomically
     updateImportJobProgress(jobId, {
       status: "running",

packages/core/src/metadata.ts

@@ -118,15 +118,15 @@ function fireAndForgetEnrichment(
   backdropPath: string | null | undefined,
   type: "movie" | "tv",
 ) {
-  refreshAvailability(titleId).catch((err) => log.debug("Availability enrichment failed:", err));
+  refreshAvailability(titleId).catch((err) => log.warn("Availability enrichment failed:", err));
   refreshRecommendations(titleId).catch((err) =>
-    log.debug("Recommendations enrichment failed:", err),
+    log.warn("Recommendations enrichment failed:", err),
   );
   syncTitleArt(titleId, posterPath, backdropPath, type).catch((err) =>
-    log.debug("Cache/thumbhash failed:", err),
+    log.warn("Cache/thumbhash failed:", err),
   );
-  refreshCredits(titleId).catch((err) => log.debug("Credits enrichment failed:", err));
-  refreshTrailer(titleId).catch((err) => log.debug("Trailer enrichment failed:", err));
+  refreshCredits(titleId).catch((err) => log.warn("Credits enrichment failed:", err));
+  refreshTrailer(titleId).catch((err) => log.warn("Trailer enrichment failed:", err));
 }
 
 type ImportResult = ReturnType<typeof _getOrFetchTitleByTmdbId>;

packages/core/src/tracking.ts

@@ -88,6 +88,19 @@ export function logEpisodeWatchBatch(
   if (episodeIds.length === 0) return;
 
   batchInsertEpisodeWatchesTransaction(userId, episodeIds, source, watchedAt);
+
+  // Auto-set title status to in_progress for affected titles
+  const titleIds = new Set<string>();
+  for (const episodeId of episodeIds) {
+    const titleId = getEpisodeTitleId(episodeId);
+    if (titleId) titleIds.add(titleId);
+  }
+  for (const titleId of titleIds) {
+    const existing = getTitleStatus(userId, titleId);
+    if (!existing || existing.status === "watchlist") {
+      setTitleStatus(userId, titleId, "in_progress", source);
+    }
+  }
 }
 
 export function markAllEpisodesWatched(

packages/core/src/webhooks.ts

@@ -6,9 +6,10 @@ import {
   updateIntegrationLastEvent,
 } from "@sofa/db/queries/webhooks";
 import { createLogger } from "@sofa/logger";
+import { getTvDetails } from "@sofa/tmdb/client";
 
 import { resolveMovieTmdbId, resolveShowTmdbId } from "./imports/resolve";
-import { getOrFetchTitleByTmdbId } from "./metadata";
+import { getOrFetchTitleByTmdbId, refreshTvChildren } from "./metadata";
 import { logEpisodeWatch, logMovieWatch } from "./tracking";
 
 const log = createLogger("webhooks");
@@ -265,7 +266,18 @@ export async function processWebhook(
       }
 
       // Find the episode in our DB
-      const season = findSeasonByTitleAndNumber(title.id, resolved.seasonNumber);
+      let season = findSeasonByTitleAndNumber(title.id, resolved.seasonNumber);
+
+      if (!season) {
+        // Season might be newly released — try refreshing from TMDB
+        try {
+          const show = await getTvDetails(resolved.showTmdbId);
+          await refreshTvChildren(title.id, resolved.showTmdbId, show.number_of_seasons);
+          season = findSeasonByTitleAndNumber(title.id, resolved.seasonNumber);
+        } catch (err) {
+          log.warn(`Failed to refresh seasons for TMDB ${resolved.showTmdbId}:`, err);
+        }
+      }
 
       if (!season) {
         logEvent(connectionId, event, "error", `Season ${resolved.seasonNumber} not found`);

packages/db/src/client.ts

@@ -89,7 +89,7 @@ export function optimizeDatabase() {
 }
 
 export function vacuumDatabase(into: string): void {
-  getClient().run("VACUUM INTO ?", [into.replace(/'/g, "''")]);
+  getClient().run("VACUUM INTO ?", [into]);
 }
 
 export function isDatabaseAccessBlocked(): boolean {