fix(bubble): recover off-screen position from disconnected monitor

Saved bubble_positions could land on a secondary monitor that was later
disconnected, leaving the bubble created off-screen with no visual feedback
on toggle-show.

- settings::load now drops any position whose 140px probe rect intersects
  no connected monitor (MonitorFromRect + MONITOR_DEFAULTTONULL).
- bubble::create calls clamp_into_work_area before the first render as a
  defense-in-depth catch for partial overflows or load/create monitor races.
- clamp_into_work_area preserves the Codex-above-Claude stagger from
  default_position when both bubbles get clamped to the same corner.
- Added info/warn log lines on create + clamp paths so future visibility
  bugs are diagnosable via --diagnose.

src/bubble.rs

@@ -133,16 +133,16 @@ pub fn create(config: BubbleConfig) -> HWND {
     let initial_size_logical = config
         .size_logical
         .clamp(MIN_BUBBLE_SIZE, MAX_BUBBLE_SIZE);
+    let dpi_for_create = primary_dpi();
+    let width_px = scale_to_dpi(initial_size_logical, dpi_for_create);
+    let height_px = scale_to_dpi(bubble_height_logical(initial_size_logical), dpi_for_create);
+    let (x, y) = config
+        .position
+        .unwrap_or_else(|| default_position(width_px, height_px, config.model));
     let hwnd = unsafe {
         let class_w = wide_str(CLASS_NAME);
         let title_w = wide_str("Claude Code Usage Bubble");
         let hinstance = GetModuleHandleW(PCWSTR::null()).unwrap_or_default();
-        let dpi = primary_dpi();
-        let width_px = scale_to_dpi(initial_size_logical, dpi);
-        let height_px = scale_to_dpi(bubble_height_logical(initial_size_logical), dpi);
-        let (x, y) = config
-            .position
-            .unwrap_or_else(|| default_position(width_px, height_px, config.model));
         CreateWindowExW(
             WS_EX_TOOLWINDOW | WS_EX_LAYERED | WS_EX_TOPMOST | WS_EX_NOACTIVATE,
             PCWSTR::from_raw(class_w.as_ptr()),
@@ -217,6 +217,16 @@ pub fn create(config: BubbleConfig) -> HWND {
         },
     );
 
+    log::info!(
+        "bubble create model={:?} pos=({x},{y}) size={width_px}x{height_px} dpi={dpi}",
+        config.model
+    );
+
+    // Defense in depth: settings::load already validates positions against
+    // currently-connected monitors, but a monitor unplug between load and
+    // create (or a partially-off-screen saved position) is still possible.
+    clamp_into_work_area(hwnd);
+
     render(hwnd);
     unsafe {
         let _ = ShowWindow(hwnd, SW_SHOWNOACTIVATE);
@@ -792,8 +802,26 @@ fn clamp_into_work_area(hwnd: HWND) {
     let w = r.right - r.left;
     let h = r.bottom - r.top;
     let nx = r.left.clamp(wa.left, (wa.right - w).max(wa.left));
-    let ny = r.top.clamp(wa.top, (wa.bottom - h).max(wa.top));
+    let mut ny = r.top.clamp(wa.top, (wa.bottom - h).max(wa.top));
+
+    // When both bubbles get clamped to the same bottom-right corner (e.g.,
+    // saved positions were on a disconnected monitor and the validator missed
+    // them), keep the Codex-above-Claude stagger that `default_position` uses
+    // so they don't visually stack.
+    let is_codex = lock_bubbles()
+        .get(&(hwnd.0 as isize))
+        .is_some_and(|b| matches!(b.model, TrayIconKind::ChatGpt));
+    if is_codex && nx == wa.right - w && ny == wa.bottom - h {
+        const STAGGER_GAP: i32 = 24;
+        ny = (ny - h - STAGGER_GAP).max(wa.top);
+    }
+
     if nx != r.left || ny != r.top {
+        log::warn!(
+            "clamp_into_work_area moved bubble from ({}, {}) to ({nx}, {ny})",
+            r.left,
+            r.top
+        );
         unsafe {
             let _ = SetWindowPos(
                 hwnd,

src/settings.rs

@@ -1,11 +1,18 @@
 use std::path::PathBuf;
 
 use serde::{Deserialize, Serialize};
+use windows::Win32::Foundation::RECT;
+use windows::Win32::Graphics::Gdi::{MonitorFromRect, MONITOR_DEFAULTTONULL};
 
 use crate::bubble::DEFAULT_BUBBLE_SIZE;
 use crate::usage::ProviderId;
 type TrayIconKind = ProviderId;
 
+// 140px matches MIN_BUBBLE_SIZE — a saved top-left a few px past the work-area
+// edge still passes the validator, but a position fully on a disconnected
+// monitor (the bug we're guarding against) fails.
+const POSITION_PROBE_PX: i32 = 140;
+
 const APP_DIR_NAME: &str = "ClaudeCodeUsageBubble";
 const SETTINGS_FILE: &str = "settings.json";
 
@@ -67,6 +74,37 @@ impl BubblePositions {
         self.claude = None;
         self.codex = None;
     }
+
+    /// Drop any saved position whose top-left no longer falls on a connected
+    /// monitor. Guards against `bubble::create` placing the window on a
+    /// disconnected secondary monitor (where the user can't see or recover it).
+    pub fn validate(&mut self) {
+        if let Some((x, y)) = self.claude {
+            if !position_on_any_monitor(x, y) {
+                log::warn!("bubble position claude ({x},{y}) outside all monitors; resetting to default");
+                self.claude = None;
+            }
+        }
+        if let Some((x, y)) = self.codex {
+            if !position_on_any_monitor(x, y) {
+                log::warn!("bubble position codex ({x},{y}) outside all monitors; resetting to default");
+                self.codex = None;
+            }
+        }
+    }
+}
+
+fn position_on_any_monitor(x: i32, y: i32) -> bool {
+    // MONITOR_DEFAULTTONULL returns a null HMONITOR when the rect intersects
+    // no connected monitor — exactly the signal we want.
+    let probe = RECT {
+        left: x,
+        top: y,
+        right: x + POSITION_PROBE_PX,
+        bottom: y + POSITION_PROBE_PX,
+    };
+    let monitor = unsafe { MonitorFromRect(&probe, MONITOR_DEFAULTTONULL) };
+    !monitor.is_invalid()
 }
 
 #[derive(Debug, Clone, Serialize, Deserialize)]
@@ -132,6 +170,8 @@ pub fn load() -> Settings {
     settings.bubble_size_logical = settings
         .bubble_size_logical
         .clamp(crate::bubble::MIN_BUBBLE_SIZE, crate::bubble::MAX_BUBBLE_SIZE);
+    // Drop positions on monitors that have since been disconnected.
+    settings.bubble_positions.validate();
     settings
 }