diff --git a/CHANGELOG.md b/CHANGELOG.md
index eb2f281d857..8ff65d82fdd 100644
--- a/CHANGELOG.md
+++ b/CHANGELOG.md
@@ -63,6 +63,8 @@ Docs: https://docs.openclaw.ai
 
 ### Fixes
 
+- Plugins/loader: do not retry native-loaded JavaScript plugin modules through the source transformer after native evaluation has already reached a missing dependency, avoiding duplicate top-level side effects. Thanks @vincentkoc.
+- Plugins/packages: reject blank `openclaw.runtimeExtensions` entries instead of silently ignoring them and falling back to inferred TypeScript runtime entries. Thanks @vincentkoc.
 - Doctor/plugins: remove stale managed npm plugin shadow entries from the managed package lock as well as `package.json` and `node_modules`, so future npm operations do not keep referencing repaired bundled-plugin shadows. Thanks @vincentkoc.
 - Plugins/runtime state: keep the key being registered when namespace eviction runs in the same millisecond as existing entries, so `register` and `registerIfAbsent` do not report success while evicting their own fresh value. Thanks @vincentkoc.
 - Control UI/Talk: make failed Talk startup errors dismissable and clear the stale Talk error state when dismissed, so missing realtime voice provider configuration does not leave a permanent chat banner. Fixes #77071. Thanks @ijoshdavis.
@@ -86,6 +88,7 @@ Docs: https://docs.openclaw.ai
 - Google Meet: fork the caller's current agent transcript into agent-mode meeting consultant sessions, so Meet replies inherit the context from the tool call that joined the meeting.
 - iOS/mobile pairing: reject non-loopback `ws://` setup URLs before QR/setup-code issuance and let the iOS Gateway settings screen scan QR codes or paste full setup-code messages. Thanks @BunsDev.
 - Control UI: keep Gateway Access inputs and locale picker contained inside the card at narrow and tablet widths.
+- Agents/trajectory: bound runtime trajectory capture and yield queued sidecar writes so oversized traces stop recording instead of monopolizing Gateway cleanup. Fixes #77124. Thanks @loyur.
 - Telegram/streaming: sanitize tool-progress draft preview backticks before shared compaction, so long backtick-heavy progress text still renders inside the safe code-formatted preview instead of collapsing to an ellipsis.
 - UI/chat: remove the unsupported `line-clamp` declaration from the chat queue text rule to eliminate Firefox console noise without changing visible truncation behavior. Thanks @ZanderH-code.
 - Agents/Pi: suppress persistence for synthetic mid-turn overflow continuation prompts, so transcript-retry recovery does not write the "continue from transcript" prompt as a new user turn. Thanks @vincentkoc.
@@ -111,6 +114,7 @@ Docs: https://docs.openclaw.ai
 - Web search: keep first-class assistant `web_search` auto-detect and configured runtime providers visible when active runtime metadata or the active plugin registry is incomplete. Fixes #77073. Thanks @joeykrug.
 - Plugins/tools: mark manifest-optional sibling tools as optional even when they come from a shared non-optional factory, so cached/status/MCP metadata keeps opt-in tool policy accurate. Thanks @vincentkoc.
 - Matrix: keep `streaming.progress.toolProgress` scoped to progress draft mode, so partial and quiet Matrix previews do not lose tool progress unless `streaming.preview.toolProgress` is disabled. Thanks @vincentkoc.
+- Gateway/validation: isolate gateway server validation files, ignore unrelated startup logs in request-trace coverage, and fail fast on stuck shared-auth sockets, reducing false main-branch CI failures for contributors. Thanks @amknight.
 - Channels/streaming: keep `streaming.progress.toolProgress` scoped to progress draft mode, so disabling compact progress lines does not silence partial/block preview tool updates. Thanks @vincentkoc.
 - Plugins/update: treat OpenClaw stable correction versions like `2026.5.3-1` as stable releases for npm installs, plugin updates, and bundled-version comparisons, so `latest` can advance official plugins without prerelease opt-in. Thanks @vincentkoc.
 - Control UI: point the Appearance tweakcn browse action and docs at the live tweakcn editor route instead of the removed `/themes` page. Fixes #77048.
diff --git a/docs/tools/trajectory.md b/docs/tools/trajectory.md
index 27699d9ee04..b6f8eb0598a 100644
--- a/docs/tools/trajectory.md
+++ b/docs/tools/trajectory.md
@@ -181,7 +181,7 @@ OpenClaw redacts sensitive values before writing export files:
 
 The exporter also bounds input size:
 
-- runtime sidecar files: 50 MiB
+- runtime sidecar files: live capture stops at 10 MiB and records a truncation event when space remains; export accepts existing runtime sidecars up to 50 MiB
 - session files: 50 MiB
 - runtime events: 200,000
 - total exported events: 250,000
diff --git a/scripts/e2e/crestodian-planner-docker-client.ts b/scripts/e2e/crestodian-planner-docker-client.mjs
similarity index 82%
rename from scripts/e2e/crestodian-planner-docker-client.ts
rename to scripts/e2e/crestodian-planner-docker-client.mjs
index 5c604b24678..8acb6800ef0 100644
--- a/scripts/e2e/crestodian-planner-docker-client.ts
+++ b/scripts/e2e/crestodian-planner-docker-client.mjs
@@ -5,18 +5,20 @@ import fs from "node:fs/promises";
 import os from "node:os";
 import path from "node:path";
 import { clearConfigCache } from "../../dist/config/config.js";
-import type { OpenClawConfig } from "../../dist/config/types.openclaw.js";
 import { runCrestodian } from "../../dist/crestodian/crestodian.js";
-import type { RuntimeEnv } from "../../dist/runtime.js";
 
-function assert(condition: unknown, message: string): asserts condition {
+function assert(condition, message) {
   if (!condition) {
     throw new Error(message);
   }
 }
 
-function createRuntime(): { runtime: RuntimeEnv; lines: string[] } {
-  const lines: string[] = [];
+function assertOutputIncludes(output, expected, message) {
+  assert(output.includes(expected), `${message}\n\nCaptured Crestodian output:\n${output}`);
+}
+
+function createRuntime() {
+  const lines = [];
   return {
     lines,
     runtime: {
@@ -29,7 +31,7 @@ function createRuntime(): { runtime: RuntimeEnv; lines: string[] } {
   };
 }
 
-async function installFakeClaudeCli(fakeBinDir: string, promptLogPath: string): Promise<void> {
+async function installFakeClaudeCli(fakeBinDir, promptLogPath) {
   await fs.mkdir(fakeBinDir, { recursive: true });
   const scriptPath = path.join(fakeBinDir, "claude");
   await fs.writeFile(
@@ -75,20 +77,24 @@ async function main() {
     runtime.runtime,
   );
   const output = runtime.lines.join("\n");
-  assert(
-    output.includes("[crestodian] planner: claude-cli/claude-opus-4-7"),
+  assertOutputIncludes(
+    output,
+    "[crestodian] planner: claude-cli/claude-opus-4-7",
     "configless planner did not use Claude CLI fallback",
   );
-  assert(
-    output.includes("Fake Claude planner selected a typed model update."),
+  assertOutputIncludes(
+    output,
+    "Fake Claude planner selected a typed model update.",
     "planner reply was not surfaced",
   );
-  assert(
-    output.includes("[crestodian] interpreted: set default model openai/gpt-5.2"),
+  assertOutputIncludes(
+    output,
+    "[crestodian] interpreted: set default model openai/gpt-5.2",
     "planner command was not interpreted",
   );
-  assert(
-    output.includes("[crestodian] done: config.setDefaultModel"),
+  assertOutputIncludes(
+    output,
+    "[crestodian] done: config.setDefaultModel",
     "planned model update did not apply",
   );
 
@@ -99,7 +105,7 @@ async function main() {
     "planner prompt did not include docs reference context",
   );
 
-  const config = JSON.parse(await fs.readFile(configPath, "utf8")) as OpenClawConfig;
+  const config = JSON.parse(await fs.readFile(configPath, "utf8"));
   assert(
     config.agents?.defaults?.model &&
       typeof config.agents.defaults.model === "object" &&
diff --git a/scripts/e2e/crestodian-planner-docker.sh b/scripts/e2e/crestodian-planner-docker.sh
index c4093a0b2a4..d21f9a51c95 100755
--- a/scripts/e2e/crestodian-planner-docker.sh
+++ b/scripts/e2e/crestodian-planner-docker.sh
@@ -28,7 +28,7 @@ docker_e2e_run_with_harness \
   bash -lc "set -euo pipefail
     source scripts/lib/openclaw-e2e-instance.sh
     openclaw_e2e_eval_test_state_from_b64 \"\${OPENCLAW_TEST_STATE_SCRIPT_B64:?missing OPENCLAW_TEST_STATE_SCRIPT_B64}\"
-    tsx scripts/e2e/crestodian-planner-docker-client.ts
+    node scripts/e2e/crestodian-planner-docker-client.mjs
   " >"$RUN_LOG" 2>&1
 status=${PIPESTATUS[0]}
 set -e
diff --git a/src/agents/pi-embedded-subscribe.tools.extract.test.ts b/src/agents/pi-embedded-subscribe.tools.extract.test.ts
index b0c22b91f47..86ec98e417c 100644
--- a/src/agents/pi-embedded-subscribe.tools.extract.test.ts
+++ b/src/agents/pi-embedded-subscribe.tools.extract.test.ts
@@ -46,7 +46,7 @@ describe("extractMessagingToolSend", () => {
 
     expect(result?.tool).toBe("message");
     expect(result?.provider).toBe("slack");
-    expect(result?.to).toBe("channel:C1");
+    expect(result?.to).toBe("channel:c1");
   });
 
   it("accepts target alias when to is omitted", () => {
diff --git a/src/agents/queued-file-writer.test.ts b/src/agents/queued-file-writer.test.ts
index 6486d23234c..8a23f8ec1f0 100644
--- a/src/agents/queued-file-writer.test.ts
+++ b/src/agents/queued-file-writer.test.ts
@@ -80,4 +80,16 @@ describe("getQueuedFileWriter", () => {
 
     expect(fs.readFileSync(filePath, "utf8")).toBe("12345\n");
   });
+
+  it("drops writes that would exceed the pending queue cap", async () => {
+    const tmpDir = makeTempDir();
+    const filePath = path.join(tmpDir, "trace.jsonl");
+    const writer = getQueuedFileWriter(new Map(), filePath, { maxQueuedBytes: 6 });
+
+    expect(writer.write("12345\n")).toBe("queued");
+    expect(writer.write("after\n")).toBe("dropped");
+    await writer.flush();
+
+    expect(fs.readFileSync(filePath, "utf8")).toBe("12345\n");
+  });
 });
diff --git a/src/agents/queued-file-writer.ts b/src/agents/queued-file-writer.ts
index f6e8616c077..f02e5d9ef96 100644
--- a/src/agents/queued-file-writer.ts
+++ b/src/agents/queued-file-writer.ts
@@ -2,14 +2,18 @@ import nodeFs from "node:fs";
 import fs from "node:fs/promises";
 import path from "node:path";
 
+export type QueuedFileWriteResult = "queued" | "dropped";
+
 export type QueuedFileWriter = {
   filePath: string;
-  write: (line: string) => void;
+  write: (line: string) => unknown;
   flush: () => Promise<void>;
 };
 
 type QueuedFileWriterOptions = {
   maxFileBytes?: number;
+  maxQueuedBytes?: number;
+  yieldBeforeWrite?: boolean;
 };
 
 type QueuedFileAppendFlagConstants = Pick<
@@ -111,6 +115,12 @@ async function safeAppendFile(
   }
 }
 
+function waitForImmediate(): Promise<void> {
+  return new Promise((resolve) => {
+    setImmediate(resolve);
+  });
+}
+
 export function getQueuedFileWriter(
   writers: Map<string, QueuedFileWriter>,
   filePath: string,
@@ -123,15 +133,29 @@ export function getQueuedFileWriter(
 
   const dir = path.dirname(filePath);
   const ready = fs.mkdir(dir, { recursive: true, mode: 0o700 }).catch(() => undefined);
-  let queue = Promise.resolve();
+  let queue: Promise<unknown> = Promise.resolve();
+  let queuedBytes = 0;
 
   const writer: QueuedFileWriter = {
     filePath,
     write: (line: string) => {
+      const lineBytes = Buffer.byteLength(line, "utf8");
+      if (
+        options.maxQueuedBytes !== undefined &&
+        queuedBytes + lineBytes > options.maxQueuedBytes
+      ) {
+        return "dropped";
+      }
+      queuedBytes += lineBytes;
       queue = queue
         .then(() => ready)
+        .then(() => (options.yieldBeforeWrite ? waitForImmediate() : undefined))
         .then(() => safeAppendFile(filePath, line, options))
-        .catch(() => undefined);
+        .catch(() => undefined)
+        .finally(() => {
+          queuedBytes = Math.max(0, queuedBytes - lineBytes);
+        });
+      return "queued";
     },
     flush: async () => {
       await queue;
diff --git a/src/auto-reply/reply/followup-delivery.test.ts b/src/auto-reply/reply/followup-delivery.test.ts
index 59cf07f42a9..64cdbb8133c 100644
--- a/src/auto-reply/reply/followup-delivery.test.ts
+++ b/src/auto-reply/reply/followup-delivery.test.ts
@@ -1,7 +1,11 @@
-import { describe, expect, it } from "vitest";
+import { describe, expect, it, vi } from "vitest";
 import type { OpenClawConfig } from "../../config/config.js";
 import { resolveFollowupDeliveryPayloads } from "./followup-delivery.js";
 
+vi.mock("../../channels/plugins/index.js", () => ({
+  getChannelPlugin: () => undefined,
+}));
+
 const baseConfig = {} as OpenClawConfig;
 
 describe("resolveFollowupDeliveryPayloads", () => {
diff --git a/src/channels/plugins/module-loader.test.ts b/src/channels/plugins/module-loader.test.ts
index e9a9b0cca90..67876b8848d 100644
--- a/src/channels/plugins/module-loader.test.ts
+++ b/src/channels/plugins/module-loader.test.ts
@@ -82,7 +82,7 @@ describe("channel plugin module loader helpers", () => {
     expect(createJiti).not.toHaveBeenCalled();
   });
 
-  it("loads TypeScript channel plugin modules through Jiti when no native hook exists", async () => {
+  it("loads TypeScript channel plugin modules through Jiti when native loading is unavailable", async () => {
     const loadWithJiti = vi.fn((target: string) => ({
       loadedBy: "jiti",
       target,
@@ -103,7 +103,7 @@ describe("channel plugin module loader helpers", () => {
     const rootDir = createTempDir();
     const modulePath = path.join(rootDir, "extensions", "demo", "index.ts");
     fs.mkdirSync(path.dirname(modulePath), { recursive: true });
-    fs.writeFileSync(modulePath, "export const ok = true;\n", "utf8");
+    fs.writeFileSync(modulePath, 'throw new Error("native source load failed");\n', "utf8");
 
     try {
       expect(
diff --git a/src/gateway/server-http.request-trace.test.ts b/src/gateway/server-http.request-trace.test.ts
index e45e6898bde..8ccd5039c07 100644
--- a/src/gateway/server-http.request-trace.test.ts
+++ b/src/gateway/server-http.request-trace.test.ts
@@ -88,9 +88,13 @@ describe("gateway HTTP request trace scope", () => {
       expect(activeTraceInHandler?.spanId).toMatch(/^[0-9a-f]{16}$/);
       expect(events).toEqual([{ trace: activeTraceInHandler, type: "message.queued" }]);
 
-      const [line] = fs.readFileSync(logPath, "utf8").trim().split("\n");
-      const record = JSON.parse(line ?? "{}") as Record<string, unknown>;
-      expect(record).toMatchObject({
+      const traceRecord = fs
+        .readFileSync(logPath, "utf8")
+        .trim()
+        .split("\n")
+        .map((line) => JSON.parse(line) as Record<string, unknown>)
+        .find((record) => record.message === "handled request trace");
+      expect(traceRecord).toMatchObject({
         traceId: activeTraceInHandler?.traceId,
         spanId: activeTraceInHandler?.spanId,
       });
diff --git a/src/gateway/server-network-runtime.e2e.test.ts b/src/gateway/server-network-runtime.e2e.test.ts
index 03bd74ea8a6..e97ff7c55d1 100644
--- a/src/gateway/server-network-runtime.e2e.test.ts
+++ b/src/gateway/server-network-runtime.e2e.test.ts
@@ -38,6 +38,14 @@ function isEnvHttpProxyDispatcher(dispatcher: unknown): boolean {
   );
 }
 
+async function closeTestDispatcher(dispatcher: unknown): Promise<void> {
+  const close = (dispatcher as { close?: () => Promise<void> | void } | undefined)?.close;
+  if (typeof close !== "function") {
+    return;
+  }
+  await close.call(dispatcher);
+}
+
 describe("gateway network runtime", () => {
   beforeEach(() => {
     clearRuntimeConfigSnapshot();
@@ -64,7 +72,8 @@ describe("gateway network runtime", () => {
     let server: Awaited<ReturnType<typeof startGatewayServer>> | undefined;
 
     try {
-      setGlobalDispatcher(new Agent());
+      const testDispatcher = new Agent();
+      setGlobalDispatcher(testDispatcher);
       for (const key of NETWORK_GATEWAY_ENV_KEYS) {
         delete process.env[key];
       }
@@ -101,7 +110,11 @@ describe("gateway network runtime", () => {
       expect(isEnvHttpProxyDispatcher(getGlobalDispatcher())).toBe(true);
     } finally {
       await server?.close({ reason: "gateway proxy bootstrap test complete" });
+      const dispatcherToClose = getGlobalDispatcher();
       setGlobalDispatcher(originalDispatcher);
+      if (dispatcherToClose !== originalDispatcher) {
+        await closeTestDispatcher(dispatcherToClose);
+      }
       await fs.rm(tempHome, { recursive: true, force: true });
       envSnapshot.restore();
     }
diff --git a/src/gateway/shared-auth.test-helpers.ts b/src/gateway/shared-auth.test-helpers.ts
index b589087e28d..8fe2462c741 100644
--- a/src/gateway/shared-auth.test-helpers.ts
+++ b/src/gateway/shared-auth.test-helpers.ts
@@ -2,10 +2,42 @@ import { expect } from "vitest";
 import { WebSocket } from "ws";
 import { connectOk, rpcReq, trackConnectChallengeNonce } from "./test-helpers.js";
 
-export async function openAuthenticatedGatewayWs(port: number, token: string): Promise<WebSocket> {
+export async function openAuthenticatedGatewayWs(
+  port: number,
+  token: string,
+  timeoutMs = 10_000,
+): Promise<WebSocket> {
   const ws = new WebSocket(`ws://127.0.0.1:${port}`);
   trackConnectChallengeNonce(ws);
-  await new Promise<void>((resolve) => ws.once("open", resolve));
+  await new Promise<void>((resolve, reject) => {
+    const cleanup = () => {
+      clearTimeout(timer);
+      ws.off("open", onOpen);
+      ws.off("error", onError);
+      ws.off("close", onClose);
+    };
+    const onOpen = () => {
+      cleanup();
+      resolve();
+    };
+    const onError = (error: unknown) => {
+      cleanup();
+      reject(error instanceof Error ? error : new Error(String(error)));
+    };
+    const onClose = (code: number, reason: Buffer) => {
+      cleanup();
+      reject(new Error(`gateway websocket closed before open (${code}: ${reason.toString()})`));
+    };
+    const timer = setTimeout(() => {
+      cleanup();
+      ws.close();
+      reject(new Error(`gateway websocket did not open within ${timeoutMs}ms`));
+    }, timeoutMs);
+    timer.unref?.();
+    ws.once("open", onOpen);
+    ws.once("error", onError);
+    ws.once("close", onClose);
+  });
   await connectOk(ws, { token });
   return ws;
 }
@@ -17,8 +49,11 @@ export async function waitForGatewayWsClose(
   return await new Promise((resolve, reject) => {
     const timer = setTimeout(() => {
       ws.off("close", onClose);
-      reject(new Error(`gateway websocket did not close within ${timeoutMs}ms`));
+      reject(
+        new Error(`gateway websocket did not close within ${timeoutMs}ms (state=${ws.readyState})`),
+      );
     }, timeoutMs);
+    timer.unref?.();
     const onClose = (code: number, reason: Buffer) => {
       clearTimeout(timer);
       resolve({ code, reason: reason.toString() });
diff --git a/src/plugin-sdk/channel-entry-contract.test.ts b/src/plugin-sdk/channel-entry-contract.test.ts
index ecea63e15b6..3521011cb2b 100644
--- a/src/plugin-sdk/channel-entry-contract.test.ts
+++ b/src/plugin-sdk/channel-entry-contract.test.ts
@@ -285,7 +285,7 @@ describe("loadBundledEntryExportSync", () => {
   });
 
   it("keeps Windows dist sidecar loads off source-transform loading", async () => {
-    const createJiti = vi.fn(() => vi.fn(() => ({ load: 42 })));
+    const createJiti = vi.fn(() => vi.fn(() => ({ load: 0 })));
     stubPluginModuleLoaderJitiFactory(createJiti as unknown as PluginModuleLoaderFactory);
     const platformSpy = vi.spyOn(process, "platform", "get").mockReturnValue("win32");
 
@@ -300,22 +300,17 @@ describe("loadBundledEntryExportSync", () => {
       fs.mkdirSync(pluginRoot, { recursive: true });
 
       const importerPath = path.join(pluginRoot, "index.js");
-      const helperPath = path.join(pluginRoot, "helper.ts");
+      const helperPath = path.join(pluginRoot, "helper.cjs");
       fs.writeFileSync(importerPath, "export default {};\n", "utf8");
-      fs.writeFileSync(helperPath, "export const load = 42;\n", "utf8");
+      fs.writeFileSync(helperPath, "module.exports = { load: 42 };\n", "utf8");
 
       expect(
         channelEntryContract.loadBundledEntryExportSync<number>(pathToFileURL(importerPath).href, {
-          specifier: "./helper.ts",
+          specifier: "./helper.cjs",
           exportName: "load",
         }),
       ).toBe(42);
-      expect(createJiti).toHaveBeenCalledWith(
-        expect.any(String),
-        expect.objectContaining({
-          tryNative: false,
-        }),
-      );
+      expect(createJiti).not.toHaveBeenCalled();
     } finally {
       platformSpy.mockRestore();
     }
diff --git a/src/plugins/discovery.test.ts b/src/plugins/discovery.test.ts
index a5f8a483c34..7536b0d8c31 100644
--- a/src/plugins/discovery.test.ts
+++ b/src/plugins/discovery.test.ts
@@ -928,6 +928,34 @@ describe("discoverOpenClawPlugins", () => {
     ).toBe(true);
   });
 
+  it("rejects blank package runtimeExtensions before falling back to inferred entries", async () => {
+    const stateDir = makeTempDir();
+    const pluginDir = path.join(stateDir, "extensions", "runtime-blank-pack");
+    mkdirSafe(path.join(pluginDir, "src"));
+    mkdirSafe(path.join(pluginDir, "dist"));
+
+    writePluginPackageManifest({
+      packageDir: pluginDir,
+      packageName: "@openclaw/runtime-blank-pack",
+      extensions: ["./src/index.ts"],
+      runtimeExtensions: [" "],
+    });
+    writePluginEntry(path.join(pluginDir, "src", "index.ts"));
+    writePluginEntry(path.join(pluginDir, "dist", "index.js"));
+
+    const result = await discoverWithStateDir(stateDir, {});
+
+    expectCandidatePresence(result, { absent: ["runtime-blank-pack"] });
+    expect(
+      result.diagnostics.some(
+        (entry) =>
+          entry.level === "error" &&
+          entry.message.includes("openclaw.runtimeExtensions[0]") &&
+          entry.message.includes("non-empty string"),
+      ),
+    ).toBe(true);
+  });
+
   it("infers built dist entries for installed TypeScript package plugins", async () => {
     const stateDir = makeTempDir();
     const pluginDir = path.join(stateDir, "extensions", "built-peer-pack");
diff --git a/src/plugins/install.test.ts b/src/plugins/install.test.ts
index 2416408024a..a74f63ef93b 100644
--- a/src/plugins/install.test.ts
+++ b/src/plugins/install.test.ts
@@ -985,6 +985,37 @@ describe("installPluginFromArchive", () => {
     }
   });
 
+  it("rejects package installs when runtimeExtensions contains a blank entry", async () => {
+    const { pluginDir, extensionsDir } = setupPluginInstallDirs();
+    fs.mkdirSync(path.join(pluginDir, "src"), { recursive: true });
+    fs.mkdirSync(path.join(pluginDir, "dist"), { recursive: true });
+    fs.writeFileSync(
+      path.join(pluginDir, "package.json"),
+      JSON.stringify({
+        name: "runtime-blank-plugin",
+        version: "1.0.0",
+        openclaw: {
+          extensions: ["./src/index.ts"],
+          runtimeExtensions: [" "],
+        },
+      }),
+    );
+    fs.writeFileSync(path.join(pluginDir, "src", "index.ts"), "export {};\n");
+    fs.writeFileSync(path.join(pluginDir, "dist", "index.js"), "export {};\n");
+
+    const result = await installPluginFromDir({
+      dirPath: pluginDir,
+      extensionsDir,
+    });
+
+    expect(result.ok).toBe(false);
+    if (!result.ok) {
+      expect(result.code).toBe(PLUGIN_INSTALL_ERROR_CODE.INVALID_OPENCLAW_EXTENSIONS);
+      expect(result.error).toContain("openclaw.runtimeExtensions[0]");
+      expect(result.error).toContain("non-empty string");
+    }
+  });
+
   it("rejects package installs when runtimeSetupEntry is missing", async () => {
     const { pluginDir, extensionsDir } = setupPluginInstallDirs();
     fs.mkdirSync(path.join(pluginDir, "src"), { recursive: true });
diff --git a/src/plugins/loader.test.ts b/src/plugins/loader.test.ts
index 4bae4812fdf..13b063810b9 100644
--- a/src/plugins/loader.test.ts
+++ b/src/plugins/loader.test.ts
@@ -1037,7 +1037,8 @@ describe("loadOpenClawPlugins", () => {
       },
     });
 
-    expect(registry.plugins.find((entry) => entry.id === "discord")?.status).toBe("loaded");
+    const record = registry.plugins.find((entry) => entry.id === "discord");
+    expect(record?.status, record?.error).toBe("loaded");
   });
   it("registers standalone text transforms", () => {
     useNoBundledPlugins();
@@ -6591,7 +6592,7 @@ module.exports = {
       }),
     );
     const record = registry.plugins.find((entry) => entry.id === "legacy-root-import");
-    expect(record?.status).toBe("loaded");
+    expect(record?.status, record?.error).toBe("loaded");
   });
 
   it("supports legacy plugins subscribing to diagnostic events from the root sdk", async () => {
@@ -6639,7 +6640,7 @@ module.exports = {
       const record = registry.plugins.find(
         (entry) => entry.id === "legacy-root-diagnostic-listener",
       );
-      expect(record?.status).toBe("loaded");
+      expect(record?.status, record?.error).toBe("loaded");
 
       emitDiagnosticEvent({
         type: "model.usage",
diff --git a/src/plugins/native-module-require.test.ts b/src/plugins/native-module-require.test.ts
index 6566a930aa0..67e97a1c7e3 100644
--- a/src/plugins/native-module-require.test.ts
+++ b/src/plugins/native-module-require.test.ts
@@ -64,6 +64,19 @@ describe("tryNativeRequireJavaScriptModule", () => {
     );
   });
 
+  it("declines missing dependency errors when source-transform fallback is available", () => {
+    const dir = makeTempDir();
+    const modulePath = path.join(dir, "plugin.cjs");
+    fs.writeFileSync(modulePath, 'require("openclaw/plugin-sdk");\n', "utf8");
+
+    expect(
+      tryNativeRequireJavaScriptModule(modulePath, {
+        allowWindows: true,
+        fallbackOnMissingDependency: true,
+      }),
+    ).toEqual({ ok: false });
+  });
+
   it("propagates real module evaluation errors instead of falling back", () => {
     const dir = makeTempDir();
     const modulePath = path.join(dir, "plugin.cjs");
diff --git a/src/plugins/native-module-require.ts b/src/plugins/native-module-require.ts
index a89d7beb723..e70a1079722 100644
--- a/src/plugins/native-module-require.ts
+++ b/src/plugins/native-module-require.ts
@@ -33,7 +33,7 @@ function isSourceTransformFallbackError(error: unknown, modulePath: string): boo
 
 export function tryNativeRequireJavaScriptModule(
   modulePath: string,
-  options: { allowWindows?: boolean } = {},
+  options: { allowWindows?: boolean; fallbackOnMissingDependency?: boolean } = {},
 ): { ok: true; moduleExport: unknown } | { ok: false } {
   if (process.platform === "win32" && options.allowWindows !== true) {
     return { ok: false };
@@ -44,7 +44,15 @@ export function tryNativeRequireJavaScriptModule(
   try {
     return { ok: true, moduleExport: nodeRequire(modulePath) };
   } catch (error) {
-    if (!isSourceTransformFallbackError(error, modulePath)) {
+    const code =
+      error && typeof error === "object" ? (error as { code?: unknown }).code : undefined;
+    if (
+      !isSourceTransformFallbackError(error, modulePath) &&
+      !(
+        options.fallbackOnMissingDependency === true &&
+        (code === "MODULE_NOT_FOUND" || code === "ERR_MODULE_NOT_FOUND")
+      )
+    ) {
       throw error;
     }
     return { ok: false };
diff --git a/src/plugins/package-entry-resolution.ts b/src/plugins/package-entry-resolution.ts
index f117562abd6..b92f55ea393 100644
--- a/src/plugins/package-entry-resolution.ts
+++ b/src/plugins/package-entry-resolution.ts
@@ -21,6 +21,8 @@ type RuntimeExtensionsResolution =
   | { ok: true; runtimeExtensions: string[] }
   | { ok: false; error: string };
 
+type PackageManifestStringList = { ok: true; entries: string[] } | { ok: false; error: string };
+
 function runtimeExtensionsLengthMismatchMessage(params: {
   runtimeExtensionsLength: number;
   extensionsLength: number;
@@ -31,11 +33,25 @@ function runtimeExtensionsLengthMismatchMessage(params: {
   );
 }
 
-function normalizePackageManifestStringList(value: unknown): string[] {
-  if (!Array.isArray(value)) {
-    return [];
+function readPackageManifestStringList(params: {
+  fieldName: string;
+  value: unknown;
+}): PackageManifestStringList {
+  if (!Array.isArray(params.value)) {
+    return { ok: true, entries: [] };
   }
-  return value.map((entry) => normalizeOptionalString(entry) ?? "").filter(Boolean);
+  const entries: string[] = [];
+  for (const [index, entry] of params.value.entries()) {
+    const normalized = normalizeOptionalString(entry);
+    if (!normalized) {
+      return {
+        ok: false,
+        error: `package.json ${params.fieldName}[${index}] must be a non-empty string`,
+      };
+    }
+    entries.push(normalized);
+  }
+  return { ok: true, entries };
 }
 
 function resolvePackageRuntimeExtensionEntries(params: {
@@ -43,7 +59,14 @@ function resolvePackageRuntimeExtensionEntries(params: {
   extensions: readonly string[];
 }): RuntimeExtensionsResolution {
   const packageManifest = getPackageManifestMetadata(params.manifest ?? undefined);
-  const runtimeExtensions = normalizePackageManifestStringList(packageManifest?.runtimeExtensions);
+  const runtimeExtensionsResult = readPackageManifestStringList({
+    fieldName: "openclaw.runtimeExtensions",
+    value: packageManifest?.runtimeExtensions,
+  });
+  if (!runtimeExtensionsResult.ok) {
+    return runtimeExtensionsResult;
+  }
+  const runtimeExtensions = runtimeExtensionsResult.entries;
   if (runtimeExtensions.length === 0) {
     return { ok: true, runtimeExtensions: [] };
   }
diff --git a/src/plugins/plugin-module-loader-cache.test.ts b/src/plugins/plugin-module-loader-cache.test.ts
index 4b29754583a..2fd80e1a34a 100644
--- a/src/plugins/plugin-module-loader-cache.test.ts
+++ b/src/plugins/plugin-module-loader-cache.test.ts
@@ -416,6 +416,48 @@ describe("getCachedPluginModuleLoader", () => {
     });
   });
 
+  it("does not source-transform fallback after native loading reaches a missing dependency", async () => {
+    const fromSourceTransformer = vi.fn();
+    const createJiti = vi.fn(() => fromSourceTransformer);
+    vi.doMock("jiti", () => ({ createJiti }));
+    const missingDependency = Object.assign(new Error("Cannot find module 'missing-dep'"), {
+      code: "MODULE_NOT_FOUND",
+    });
+    const nativeStub = vi.fn(() => {
+      throw missingDependency;
+    });
+    vi.doMock("./native-module-require.js", () => ({
+      isJavaScriptModulePath: () => true,
+      tryNativeRequireJavaScriptModule: nativeStub,
+    }));
+    const { getCachedPluginModuleLoader, getPluginModuleLoaderStats } = await importFreshModule<
+      typeof import("./plugin-module-loader-cache.js")
+    >(import.meta.url, "./plugin-module-loader-cache.js?scope=native-missing-dependency");
+
+    const cache = new Map();
+    const loader = getCachedPluginModuleLoader({
+      cache,
+      modulePath: "/repo/dist/extensions/demo/api.js",
+      importerUrl: "file:///repo/src/plugins/public-surface-loader.ts",
+      loaderFilename: "file:///repo/src/plugins/public-surface-loader.ts",
+      createLoader: asPluginModuleLoaderFactory(createJiti),
+    });
+
+    expect(() => loader("/repo/dist/extensions/demo/api.js")).toThrow("missing-dep");
+    expect(createJiti).not.toHaveBeenCalled();
+    expect(fromSourceTransformer).not.toHaveBeenCalled();
+    expect(nativeStub).toHaveBeenCalledWith("/repo/dist/extensions/demo/api.js", {
+      allowWindows: true,
+    });
+    expect(getPluginModuleLoaderStats()).toMatchObject({
+      calls: 1,
+      nativeHits: 0,
+      nativeMisses: 0,
+      sourceTransformFallbacks: 0,
+      sourceTransformForced: 0,
+    });
+  });
+
   it("falls back to source transform when the native-require helper declines", async () => {
     const fromSourceTransformer = vi.fn(() => ({ fromSourceTransform: true }));
     const createJiti = vi.fn(() => fromSourceTransformer);
diff --git a/src/plugins/plugin-module-loader-cache.ts b/src/plugins/plugin-module-loader-cache.ts
index 076dda986bc..f73850b2ba0 100644
--- a/src/plugins/plugin-module-loader-cache.ts
+++ b/src/plugins/plugin-module-loader-cache.ts
@@ -282,7 +282,9 @@ function createPluginModuleLoader(params: {
         ...rest,
       );
     }
-    const native = tryNativeRequireJavaScriptModule(target, { allowWindows: true });
+    const native = tryNativeRequireJavaScriptModule(target, {
+      allowWindows: true,
+    });
     if (native.ok) {
       pluginModuleLoaderStats.nativeHits += 1;
       return native.moduleExport;
diff --git a/src/plugins/plugin-sdk-dist-alias.ts b/src/plugins/plugin-sdk-dist-alias.ts
index e1f98c8aa74..58cddb1b31e 100644
--- a/src/plugins/plugin-sdk-dist-alias.ts
+++ b/src/plugins/plugin-sdk-dist-alias.ts
@@ -8,12 +8,7 @@ function writeRuntimeJsonFile(targetPath: string, value: unknown): void {
 
 function writeRuntimeModuleWrapper(sourcePath: string, targetPath: string): void {
   const relative = `./${path.relative(path.dirname(targetPath), sourcePath).split(path.sep).join("/")}`;
-  const content = [
-    `export * from ${JSON.stringify(relative)};`,
-    `import * as moduleExports from ${JSON.stringify(relative)};`,
-    `export default moduleExports.default ?? moduleExports;`,
-    "",
-  ].join("\n");
+  const content = [`export * from ${JSON.stringify(relative)};`, ""].join("\n");
   try {
     if (fs.readFileSync(targetPath, "utf8") === content) {
       return;
diff --git a/src/trajectory/export.test.ts b/src/trajectory/export.test.ts
index b3b23c6ec25..c6e786788b4 100644
--- a/src/trajectory/export.test.ts
+++ b/src/trajectory/export.test.ts
@@ -4,7 +4,7 @@ import path from "node:path";
 import type { Message, Usage } from "@mariozechner/pi-ai";
 import { afterAll, describe, expect, it } from "vitest";
 import { exportTrajectoryBundle, resolveDefaultTrajectoryExportDir } from "./export.js";
-import { resolveTrajectoryPointerFilePath } from "./paths.js";
+import { TRAJECTORY_RUNTIME_FILE_MAX_BYTES, resolveTrajectoryPointerFilePath } from "./paths.js";
 import type { TrajectoryEvent } from "./types.js";
 
 const tempRoot = fs.mkdtempSync(path.join(os.tmpdir(), "openclaw-trajectory-"));
@@ -272,7 +272,7 @@ describe("exportTrajectoryBundle", () => {
     const outputDir = path.join(tmpDir, "bundle");
     writeSimpleSessionFile(sessionFile);
     fs.closeSync(fs.openSync(runtimeFile, "w"));
-    fs.truncateSync(runtimeFile, 50 * 1024 * 1024 + 1);
+    fs.truncateSync(runtimeFile, TRAJECTORY_RUNTIME_FILE_MAX_BYTES + 1);
 
     await expect(
       exportTrajectoryBundle({
diff --git a/src/trajectory/paths.ts b/src/trajectory/paths.ts
index 76915989671..d2b3033830a 100644
--- a/src/trajectory/paths.ts
+++ b/src/trajectory/paths.ts
@@ -2,6 +2,7 @@ import fs from "node:fs";
 import path from "node:path";
 import { resolveHomeRelativePath } from "../infra/home-dir.js";
 
+export const TRAJECTORY_RUNTIME_CAPTURE_MAX_BYTES = 10 * 1024 * 1024;
 export const TRAJECTORY_RUNTIME_FILE_MAX_BYTES = 50 * 1024 * 1024;
 export const TRAJECTORY_RUNTIME_EVENT_MAX_BYTES = 256 * 1024;
 
diff --git a/src/trajectory/runtime.test.ts b/src/trajectory/runtime.test.ts
index c364b30dfb8..63723c76d22 100644
--- a/src/trajectory/runtime.test.ts
+++ b/src/trajectory/runtime.test.ts
@@ -88,7 +88,7 @@ describe("trajectory runtime", () => {
     expect(JSON.stringify(parsed.data)).not.toContain("sk-other-secret-token");
   });
 
-  it("truncates events that exceed the runtime event byte limit", () => {
+  it("bounds large runtime event fields before serialization", () => {
     const writes: string[] = [];
     const recorder = createTrajectoryRuntimeRecorder({
       sessionId: "session-1",
@@ -108,15 +108,53 @@ describe("trajectory runtime", () => {
 
     expect(writes).toHaveLength(1);
     const parsed = JSON.parse(writes[0]);
-    expect(parsed.data).toMatchObject({
+    expect(parsed.data.prompt).toMatchObject({
       truncated: true,
-      reason: "trajectory-event-size-limit",
+      reason: "trajectory-field-size-limit",
     });
     expect(Buffer.byteLength(writes[0], "utf8")).toBeLessThanOrEqual(
       TRAJECTORY_RUNTIME_EVENT_MAX_BYTES + 1,
     );
   });
 
+  it("stops runtime capture at the file budget and records a truncation event", async () => {
+    const writes: string[] = [];
+    const recorder = createTrajectoryRuntimeRecorder({
+      sessionId: "session-1",
+      sessionFile: "/tmp/session.jsonl",
+      maxRuntimeFileBytes: 900,
+      writer: {
+        filePath: "/tmp/session.trajectory.jsonl",
+        write: (line) => {
+          writes.push(line);
+        },
+        flush: async () => undefined,
+      },
+    });
+
+    recorder?.recordEvent("context.compiled", {
+      prompt: "x".repeat(180),
+    });
+    recorder?.recordEvent("prompt.submitted", {
+      prompt: "y".repeat(180),
+    });
+    recorder?.recordEvent("model.completed", {
+      get prompt() {
+        throw new Error("stopped recorder should not read dropped payloads");
+      },
+    });
+    await recorder?.flush();
+
+    const parsed = writes.map((line) => JSON.parse(line));
+    expect(parsed.map((event) => event.type)).toContain("trace.truncated");
+    const truncated = parsed.find((event) => event.type === "trace.truncated");
+    expect(truncated?.data).toMatchObject({
+      reason: "trajectory-runtime-file-size-limit",
+      limitBytes: 900,
+    });
+    expect(truncated?.data.droppedEvents).toBeGreaterThan(0);
+  });
+
   it("writes a session-adjacent pointer when using an override directory", () => {
     const tmpDir = makeTempDir();
     const sessionFile = path.join(tmpDir, "session.jsonl");
diff --git a/src/trajectory/runtime.ts b/src/trajectory/runtime.ts
index af2b5e1f93f..e714cd30ac2 100644
--- a/src/trajectory/runtime.ts
+++ b/src/trajectory/runtime.ts
@@ -6,6 +6,7 @@ import type { OpenClawConfig } from "../config/types.openclaw.js";
 import { parseBooleanValue } from "../utils/boolean.js";
 import { safeJsonStringify } from "../utils/safe-json.js";
 import {
+  TRAJECTORY_RUNTIME_CAPTURE_MAX_BYTES,
   TRAJECTORY_RUNTIME_EVENT_MAX_BYTES,
   TRAJECTORY_RUNTIME_FILE_MAX_BYTES,
   resolveTrajectoryFilePath,
@@ -15,6 +16,7 @@ import {
 import type { TrajectoryEvent, TrajectoryToolDefinition } from "./types.js";
 
 export {
+  TRAJECTORY_RUNTIME_CAPTURE_MAX_BYTES,
   TRAJECTORY_RUNTIME_EVENT_MAX_BYTES,
   TRAJECTORY_RUNTIME_FILE_MAX_BYTES,
   resolveTrajectoryFilePath,
@@ -26,6 +28,7 @@ export {
 type TrajectoryRuntimeInit = {
   cfg?: OpenClawConfig;
   env?: NodeJS.ProcessEnv;
+  maxRuntimeFileBytes?: number;
   runId?: string;
   sessionId: string;
   sessionKey?: string;
@@ -46,6 +49,11 @@ type TrajectoryRuntimeRecorder = {
 
 const writers = new Map<string, QueuedFileWriter>();
 const MAX_TRAJECTORY_WRITERS = 100;
+const TRAJECTORY_RUNTIME_TRUNCATION_SENTINEL_RESERVE_BYTES = 2048;
+const TRAJECTORY_RUNTIME_DATA_STRING_MAX_CHARS = 32_768;
+const TRAJECTORY_RUNTIME_DATA_ARRAY_MAX_ITEMS = 64;
+const TRAJECTORY_RUNTIME_DATA_OBJECT_MAX_KEYS = 64;
+const TRAJECTORY_RUNTIME_DATA_MAX_DEPTH = 6;
 
 function writeTrajectoryPointerBestEffort(params: {
   filePath: string;
@@ -128,6 +136,75 @@ function truncateOversizedTrajectoryEvent(
   return undefined;
 }
 
+function truncatedTrajectoryValue(reason: string, details: Record<string, unknown> = {}): unknown {
+  return {
+    truncated: true,
+    reason,
+    ...details,
+  };
+}
+
+function limitTrajectoryPayloadValue(
+  value: unknown,
+  depth = 0,
+  seen: WeakSet<object> = new WeakSet(),
+): unknown {
+  if (typeof value === "string") {
+    if (value.length > TRAJECTORY_RUNTIME_DATA_STRING_MAX_CHARS) {
+      return truncatedTrajectoryValue("trajectory-field-size-limit", {
+        originalChars: value.length,
+        limitChars: TRAJECTORY_RUNTIME_DATA_STRING_MAX_CHARS,
+      });
+    }
+    return value;
+  }
+  if (typeof value !== "object" || value === null) {
+    return value;
+  }
+  if (seen.has(value)) {
+    return truncatedTrajectoryValue("trajectory-circular-reference");
+  }
+  if (depth >= TRAJECTORY_RUNTIME_DATA_MAX_DEPTH) {
+    return truncatedTrajectoryValue("trajectory-depth-limit", {
+      limitDepth: TRAJECTORY_RUNTIME_DATA_MAX_DEPTH,
+    });
+  }
+  seen.add(value);
+  if (Array.isArray(value)) {
+    const limited = value
+      .slice(0, TRAJECTORY_RUNTIME_DATA_ARRAY_MAX_ITEMS)
+      .map((item) => limitTrajectoryPayloadValue(item, depth + 1, seen));
+    if (value.length > TRAJECTORY_RUNTIME_DATA_ARRAY_MAX_ITEMS) {
+      limited.push(
+        truncatedTrajectoryValue("trajectory-array-size-limit", {
+          originalLength: value.length,
+          limitItems: TRAJECTORY_RUNTIME_DATA_ARRAY_MAX_ITEMS,
+        }),
+      );
+    }
+    seen.delete(value);
+    return limited;
+  }
+  const record = value as Record<string, unknown>;
+  const keys = Object.keys(record);
+  const limited: Record<string, unknown> = {};
+  for (const key of keys.slice(0, TRAJECTORY_RUNTIME_DATA_OBJECT_MAX_KEYS)) {
+    limited[key] = limitTrajectoryPayloadValue(record[key], depth + 1, seen);
+  }
+  if (keys.length > TRAJECTORY_RUNTIME_DATA_OBJECT_MAX_KEYS) {
+    limited._truncated = truncatedTrajectoryValue("trajectory-object-size-limit", {
+      originalKeys: keys.length,
+      limitKeys: TRAJECTORY_RUNTIME_DATA_OBJECT_MAX_KEYS,
+    });
+  }
+  seen.delete(value);
+  return limited;
+}
+
+function sanitizeTrajectoryPayload(data: Record<string, unknown>): Record<string, unknown> {
+  return sanitizeDiagnosticPayload(limitTrajectoryPayloadValue(data)) as Record<string, unknown>;
+}
+
 export function toTrajectoryToolDefinitions(
   tools: ReadonlyArray<{ name?: string; description?: string; parameters?: unknown }>,
 ): TrajectoryToolDefinition[] {
@@ -141,7 +218,7 @@ export function toTrajectoryToolDefinitions(
         {
           name,
           description: tool.description,
-          parameters: sanitizeDiagnosticPayload(tool.parameters),
+          parameters: sanitizeDiagnosticPayload(limitTrajectoryPayloadValue(tool.parameters)),
         },
       ];
     })
@@ -167,10 +244,16 @@ export function createTrajectoryRuntimeRecorder(
   if (!params.writer) {
     trimTrajectoryWriterCache();
   }
+  const maxRuntimeFileBytes = Math.max(
+    1,
+    Math.floor(params.maxRuntimeFileBytes ?? TRAJECTORY_RUNTIME_CAPTURE_MAX_BYTES),
+  );
   const writer =
     params.writer ??
     getQueuedFileWriter(writers, filePath, {
-      maxFileBytes: TRAJECTORY_RUNTIME_FILE_MAX_BYTES,
+      maxFileBytes: maxRuntimeFileBytes,
+      maxQueuedBytes: maxRuntimeFileBytes,
+      yieldBeforeWrite: true,
     });
   writeTrajectoryPointerBestEffort({
     filePath,
@@ -179,40 +262,97 @@ export function createTrajectoryRuntimeRecorder(
   });
   let seq = 0;
   const traceId = params.sessionId;
+  const sentinelReserveBytes = Math.min(
+    TRAJECTORY_RUNTIME_TRUNCATION_SENTINEL_RESERVE_BYTES,
+    Math.floor(maxRuntimeFileBytes / 2),
+  );
+  const normalEventLimitBytes = Math.max(1, maxRuntimeFileBytes - sentinelReserveBytes);
+  let acceptedRuntimeBytes = 0;
+  let droppedEvents = 0;
+  let droppedEventBytes = 0;
+  let captureStopped = false;
+
+  const writeBoundedLine = (line: string, options: { reserveSentinel: boolean }): boolean => {
+    const jsonlLine = `${line}\n`;
+    const lineBytes = Buffer.byteLength(jsonlLine, "utf8");
+    const limitBytes = options.reserveSentinel ? normalEventLimitBytes : maxRuntimeFileBytes;
+    if (acceptedRuntimeBytes + lineBytes > limitBytes) {
+      captureStopped = true;
+      droppedEvents += 1;
+      droppedEventBytes += lineBytes;
+      return false;
+    }
+    const result = writer.write(jsonlLine);
+    if (result === "dropped") {
+      captureStopped = true;
+      droppedEvents += 1;
+      droppedEventBytes += lineBytes;
+      return false;
+    }
+    acceptedRuntimeBytes += lineBytes;
+    return true;
+  };
+
+  const buildEventLine = (type: string, data?: Record<string, unknown>): string | undefined => {
+    const nextSeq = seq + 1;
+    const event: TrajectoryEvent = {
+      traceSchema: "openclaw-trajectory",
+      schemaVersion: 1,
+      traceId,
+      source: "runtime",
+      type,
+      ts: new Date().toISOString(),
+      seq: nextSeq,
+      sourceSeq: nextSeq,
+      sessionId: params.sessionId,
+      sessionKey: params.sessionKey,
+      runId: params.runId,
+      workspaceDir: params.workspaceDir,
+      provider: params.provider,
+      modelId: params.modelId,
+      modelApi: params.modelApi,
+      data: data ? sanitizeTrajectoryPayload(data) : undefined,
+    };
+    const line = safeJsonStringify(event);
+    if (!line) {
+      return undefined;
+    }
+    const boundedLine = truncateOversizedTrajectoryEvent(event, line);
+    if (!boundedLine) {
+      return undefined;
+    }
+    seq = nextSeq;
+    return boundedLine;
+  };
 
   return {
     enabled: true,
     filePath,
     recordEvent: (type, data) => {
-      const event: TrajectoryEvent = {
-        traceSchema: "openclaw-trajectory",
-        schemaVersion: 1,
-        traceId,
-        source: "runtime",
-        type,
-        ts: new Date().toISOString(),
-        seq: (seq += 1),
-        sourceSeq: seq,
-        sessionId: params.sessionId,
-        sessionKey: params.sessionKey,
-        runId: params.runId,
-        workspaceDir: params.workspaceDir,
-        provider: params.provider,
-        modelId: params.modelId,
-        modelApi: params.modelApi,
-        data: data ? (sanitizeDiagnosticPayload(data) as Record<string, unknown>) : undefined,
-      };
-      const line = safeJsonStringify(event);
+      if (captureStopped) {
+        droppedEvents += 1;
+        return;
+      }
+      const line = buildEventLine(type, data);
       if (!line) {
         return;
       }
-      const boundedLine = truncateOversizedTrajectoryEvent(event, line);
-      if (!boundedLine) {
-        return;
-      }
-      writer.write(`${boundedLine}\n`);
+      writeBoundedLine(line, { reserveSentinel: true });
     },
     flush: async () => {
+      if (droppedEvents > 0) {
+        const line = buildEventLine("trace.truncated", {
+          reason: "trajectory-runtime-file-size-limit",
+          droppedEvents,
+          droppedEventBytes,
+          limitBytes: maxRuntimeFileBytes,
+        });
+        if (line) {
+          writeBoundedLine(line, { reserveSentinel: false });
+        }
+        droppedEvents = 0;
+        droppedEventBytes = 0;
+      }
       await writer.flush();
       if (!params.writer) {
         writers.delete(filePath);
diff --git a/test/vitest/vitest.gateway-server.config.ts b/test/vitest/vitest.gateway-server.config.ts
index a1bdcb00068..b26a8098d54 100644
--- a/test/vitest/vitest.gateway-server.config.ts
+++ b/test/vitest/vitest.gateway-server.config.ts
@@ -20,6 +20,9 @@ export function createGatewayServerVitestConfig(env?: Record<string, string | un
         "src/gateway/server.startup-matrix-migration.integration.test.ts",
         "src/gateway/sessions-history-http.test.ts",
       ],
+      // Gateway server suites share process-level env, logger, and server helper state.
+      // Isolate files so parallel shards cannot cross-wire suite-scoped servers.
+      isolate: true,
       name: "gateway-server",
     },
   );