fix(desktop): wait 5m before reconnect warning toast

Brief transport blips often self-heal in 1–3 minutes. Raise the
non-blocking escalate toast from 45s to 5m so those windows stay quiet
while chat remains readable/draftable. Confirmed reauth still takes the
full-screen recovery overlay immediately.

apps/desktop/src/app/gateway/hooks/use-gateway-boot.test.tsx

@@ -372,8 +372,9 @@ describe('useGatewayBoot remote reconnect loop (real hook, fake socket)', () =>
     act(() => FakeWebSocket.instances[0].drop())
     await flushAsync()
 
-    // Walk the backoff past the ~45s escalation threshold.
-    for (let i = 0; i < 8; i += 1) {
+    // Walk the backoff well past the historical 45s threshold and into the
+    // current multi-minute escalate window. Chat must stay unlocked either way.
+    for (let i = 0; i < 24; i += 1) {
       await advanceBackoff()
     }
 
@@ -393,7 +394,7 @@ describe('useGatewayBoot remote reconnect loop (real hook, fake socket)', () =>
     act(() => FakeWebSocket.instances[0].drop())
     await flushAsync()
 
-    for (let i = 0; i < 8; i += 1) {
+    for (let i = 0; i < 24; i += 1) {
       await advanceBackoff()
     }
 

apps/desktop/src/app/gateway/hooks/use-gateway-boot.ts

@@ -64,11 +64,15 @@ import { stashGatewaySurvivor, survivorIsStale, takeGatewaySurvivor } from './ga
 
 // After the reconnect loop has been failing for this long, raise a NON-blocking
 // warning toast. Full-screen BootFailureOverlay used to lock the user out of
-// reading/drafting for the whole 1–3 minute blip even though the transcript is
-// still on screen underneath. Confirmed reauth still escalates to the overlay
-// (Sign in is required). Time-based (not attempt-count) because full-jitter
-// backoff makes attempt counts a meaningless clock.
-const RECONNECT_ESCALATE_AFTER_MS = 45_000
+// reading/drafting for the whole blip even though the transcript is still on
+// screen underneath. Confirmed reauth still escalates to the overlay (Sign in
+// is required). Time-based (not attempt-count) because full-jitter backoff
+// makes attempt counts a meaningless clock.
+//
+// 5 minutes (not the historical ~45s) so brief transport weather — ticket mint
+// flaps, sleep/wake, Wi‑Fi blips that self-heal in 1–3 minutes — never even
+// toast. Chat stays readable/draftable the whole time either way.
+const RECONNECT_ESCALATE_AFTER_MS = 300_000
 
 // Bounded self-heal for a failed REMOTE boot (#82679): when the primary boot
 // fails on a transient remote fault (dropped SSH/HTTP registered connection,
@@ -158,9 +162,8 @@ export function useGatewayBoot({
     // identical error toasts (and their haptics). Reset on the next clean open.
     let reauthNotified = false
     // Raised once the reconnect loop has been failing for
-    // RECONNECT_ESCALATE_AFTER_MS so the recovery overlay replaces the
-    // dead-end CONNECTING screen. Reset on a clean open or a manual/
-    // wake-driven reconnect.
+    // RECONNECT_ESCALATE_AFTER_MS so we fire a single non-blocking toast.
+    // Reset on a clean open or a manual/wake-driven reconnect.
     let escalated = false
     // Bounded automatic boot retry for transient REMOTE failures (#82679).
     let bootRetryAttempt = 0

apps/desktop/src/components/gateway-connecting-overlay.test.tsx

@@ -170,14 +170,14 @@ describe('connecting overlay vs recovery surface', () => {
     expect(isRecoveryShown()).toBe(false)
   })
 
-  it('FIX: once the prolonged reconnect raises a recoverable boot error, the recovery overlay takes over', async () => {
-    // Mirrors what useGatewayBoot.scheduleReconnect() now does after ~45s of
-    // failed post-boot reconnects: it calls failDesktopBoot(), flipping the UI
-    // from the dead-end CONNECTING overlay to the recovery surface.
+  it('FIX: confirmed reauth boot.error still surfaces the recovery overlay (not CONNECTING)', async () => {
+    // Transport blips no longer set boot.error (toast + background retry).
+    // Confirmed OAuth reauth still does — and that recovery surface must win
+    // over any residual connecting state so Sign-in / Gateway settings stay reachable.
     setGatewayState('error')
     $desktopBoot.set({
       ...$desktopBoot.get(),
-      error: 'Lost connection to the Hermes gateway and could not reconnect.',
+      error: 'Your remote gateway session has expired. Sign in again.',
       running: false,
       visible: true
     })
@@ -191,7 +191,7 @@ describe('connecting overlay vs recovery surface', () => {
       )
     })
 
-    // Escape hatch is now reachable; the connecting overlay bows out.
+    // Escape hatch is reachable; the connecting overlay bows out.
     expect(isRecoveryShown()).toBe(true)
     expect(screen.getByRole('button', { name: /gateway settings/i })).toBeTruthy()
     expect(isConnectingShown()).toBe(false)