fix(settings): restore the default-calibration-profile backfill dropped in 3abfaf60

changes/unreleased/fix-calibration-default-profile.md

@@ -0,0 +1,3 @@
+### Bugfixes
+
+- **Fix Calibration Default Profile**: restore the default-calibration-profile backfill dropped when calibration ownership moved to the daemon, so fresh installs (and any install with an explicit empty `calibration_profiles` list) get a usable profile and active calibration ID instead of a permanently disabled calibration flow.

crates/skill-daemon/src/routes/settings_calibration.rs

@@ -204,9 +204,10 @@ mod tests {
 
     fn mk_state() -> (TempDir, AppState) {
         let td = TempDir::new().unwrap();
-        // Write default settings with a default calibration profile.
-        let mut settings = skill_settings::UserSettings::default();
-        settings.calibration_profiles = vec![CalibrationProfile::default()];
+        // Write default settings. calibration_profiles is left at its
+        // Vec::new() default — load_settings()'s backfill (restored from
+        // 3abfaf60) is what populates it, not this fixture.
+        let settings = skill_settings::UserSettings::default();
         let path = skill_settings::settings_path(td.path());
         if let Some(p) = path.parent() {
             std::fs::create_dir_all(p).unwrap();
@@ -216,6 +217,29 @@ mod tests {
         (td, state)
     }
 
+    /// Regression test for the backfill dropped by 3abfaf60: a settings.json
+    /// with `"calibration_profiles": []` explicitly present (not merely
+    /// missing) must still yield exactly one profile, and its id must equal
+    /// active_calibration_id (M-1 — the other half of the deleted block).
+    /// Written as raw JSON text so this cannot silently stop covering the
+    /// explicit-`[]` case if the struct ever gains `skip_serializing_if`.
+    #[tokio::test]
+    async fn list_profiles_backfills_when_explicitly_empty() {
+        let td = TempDir::new().unwrap();
+        let path = skill_settings::settings_path(td.path());
+        if let Some(p) = path.parent() {
+            std::fs::create_dir_all(p).unwrap();
+        }
+        std::fs::write(&path, r#"{"calibration_profiles": [], "active_calibration_id": ""}"#).unwrap();
+        let state = AppState::new("token".into(), td.path().to_path_buf());
+
+        let res = list_profiles(State(state.clone())).await.0;
+        assert_eq!(res.len(), 1);
+
+        let active = get_active_profile_id(State(state)).await.0;
+        assert_eq!(active["value"], res[0].id);
+    }
+
     #[tokio::test]
     async fn list_profiles_returns_defaults() {
         let (_td, state) = mk_state();

crates/skill-settings/src/lib.rs

@@ -1291,6 +1291,20 @@ pub fn load_settings(skill_dir: &Path) -> UserSettings {
         s.settings_shortcut = default_settings_shortcut();
     }
 
+    // ── Calibration migration: 3abfaf60 moved calibration ownership to the
+    // daemon and deleted the backfill that ran in the Tauri client
+    // (v0.0.121:src-tauri/src/setup.rs:370-382). Nothing re-established it
+    // daemon-side. Restore it where settings are now loaded. In-memory only,
+    // deliberately — this re-applies on every load and lands on disk
+    // incidentally, the first time any route calls modify_settings_blocking,
+    // matching the shortcut migrations directly above.
+    if s.calibration_profiles.is_empty() {
+        s.calibration_profiles = vec![CalibrationProfile::from_legacy(&s.calibration)];
+    }
+    if s.active_calibration_id.is_empty() {
+        s.active_calibration_id = s.calibration_profiles.first().map(|p| p.id.clone()).unwrap_or_default();
+    }
+
     // ── Secret migration: plaintext JSON → system keychain ───────────────
     //
     // If the JSON file still contains non-empty secret values (from a