fix(inject): heap the SwDeviceCreate callback context; stop latching a pad slot on a failed create

Two medium findings from the round-1 sweep, each applied to both siblings.

- create_swdevice stack-allocated the SwCreateCtx that the async PnP completion
  callback writes through (result + up to 127 u16 of instance id) and then
  SetEvents. The wait is bounded at 10s, so on a wedged-PnP timeout the callback
  can still be PENDING: the frame is popped, the input thread reuses that stack,
  and a late callback corrupts it and SetEvents an already-closed (possibly
  recycled) handle. The context is now heap-allocated and reclaimed only where
  the callback provably ran; on the timeout path the box is deliberately leaked
  and the event left open, so a late write always targets live memory. Costs a
  one-off ~264 B + one HANDLE on that rare path. Applied to the DualSense path
  and its XUSB sibling in gamepad_windows.rs.

- Ds4WinPad::open swallowed a create_swdevice failure into a WARN and returned
  Ok with no devnode. PadSlots::ensure then stored Some(pad) AND called
  gate.on_success(), so the slot short-circuited on is_some() forever and the
  capped-backoff retry that exists precisely to self-heal a transient PnP failure
  never ran — the game saw no controller for the rest of the session unless the
  client unplugged the pad. Now propagates, matching the XUSB sibling. Same fix
  applied to steam_deck_windows.rs.

Windows .173: pf-inject 53/0. Linux .21: pf-inject 74/0 (8 ignored).

Co-Authored-By: Claude Opus 4.8 <noreply@anthropic.com>

crates/pf-inject/src/inject/windows/dualsense_windows.rs

@@ -299,13 +299,20 @@ pub(super) fn create_swdevice(p: &SwDeviceProfile) -> Result<(HSWDEVICE, Option<
     let event = unsafe { CreateEventW(None, true, false, PCWSTR::null())? };
     // `result` starts as E_FAIL, NOT S_OK: if the wait below times out, a zero-initialised HRESULT
     // would read as success and mask the failure (found by the 2026-07 driver-health audit).
-    let mut ctx = SwCreateCtx {
+    // HEAP-allocated, deliberately: `sw_create_cb` writes `result` + up to 127 u16 of instance id
+    // through this pointer and then `SetEvent`s. The wait below is bounded (10 s), so on a wedged-PnP
+    // timeout the callback may still be PENDING — a stack context would be popped and a late callback
+    // would corrupt whatever the input thread put there next, and SetEvent a closed/recycled handle.
+    // On the timeout path we therefore LEAK the box and leave the event open (a one-off ~264 B + one
+    // HANDLE, only on that rare path) so a late callback always writes to live memory.
+    let ctx = Box::into_raw(Box::new(SwCreateCtx {
         event,
         result: E_FAIL,
         instance_id: [0; 128],
-    };
-    // SAFETY: info + the buffers + ctx outlive the call (we wait on the event before returning);
-    // windows-rs returns the HSWDEVICE (the C out-param) as the Result value.
+    }));
+    // SAFETY: info + the buffers outlive the call; `ctx` is a live heap allocation that outlives every
+    // path below (reclaimed only where the callback provably ran). windows-rs returns the HSWDEVICE
+    // (the C out-param) as the Result value.
     let hsw = match unsafe {
         SwDeviceCreate(
             w!("punktfunk"),
@@ -313,13 +320,15 @@ pub(super) fn create_swdevice(p: &SwDeviceProfile) -> Result<(HSWDEVICE, Option<
             &info,
             None,
             Some(sw_create_cb),
-            Some(&mut ctx as *mut SwCreateCtx as *const c_void),
+            Some(ctx as *const c_void),
         )
     } {
         Ok(h) => h,
         Err(e) => {
-            // SAFETY: event is valid.
+            // SAFETY: the call failed, so no callback was registered and `ctx` is ours to reclaim;
+            // `event` is valid and unreferenced.
             unsafe {
+                drop(Box::from_raw(ctx));
                 let _ = CloseHandle(event);
             }
             return Err(anyhow!("SwDeviceCreate failed: {e}"));
@@ -328,17 +337,22 @@ pub(super) fn create_swdevice(p: &SwDeviceProfile) -> Result<(HSWDEVICE, Option<
     // Block until PnP finishes enumerating (the callback signals), then check its result.
     // SAFETY: event is valid.
     let wait = unsafe { WaitForSingleObject(event, 10_000) };
-    // SAFETY: event is valid.
-    unsafe {
-        let _ = CloseHandle(event);
-    }
     if wait != WAIT_OBJECT_0 {
+        // Timed out: the callback may still fire. Intentionally leak `ctx` AND leave `event` open so
+        // its eventual write + SetEvent target live memory/handle rather than freed ones.
         // SAFETY: hsw is the handle SwDeviceCreate returned.
         unsafe { SwDeviceClose(hsw) };
         return Err(anyhow!(
             "SwDeviceCreate enumeration callback never fired (10s) — PnP may be wedged"
         ));
     }
+    // The callback ran (it is what signalled the event), so nothing else will touch `ctx`/`event`.
+    // SAFETY: `ctx` came from `Box::into_raw` above and is reclaimed exactly once here; `event` is
+    // valid and no longer referenced by a pending callback.
+    let ctx = unsafe {
+        let _ = CloseHandle(event);
+        Box::from_raw(ctx)
+    };
     if ctx.result.is_err() {
         // SAFETY: hsw is the handle SwDeviceCreate returned.
         unsafe { SwDeviceClose(hsw) };

crates/pf-inject/src/inject/windows/dualshock4_windows.rs

@@ -62,7 +62,7 @@ impl Ds4WinPad {
             std::ptr::write_unaligned(base as *mut u32, SHM_MAGIC);
         }
         let inst = format!("pf_ds4_{index}");
-        let (hsw, instance_id) = match create_swdevice(&SwDeviceProfile {
+        let (hsw, instance_id) = create_swdevice(&SwDeviceProfile {
             instance: &inst,
             container_tag: 0x5046_4453, // "PFDS"
             container_index: index,
@@ -70,13 +70,13 @@ impl Ds4WinPad {
             usb_vid_pid: "VID_054C&PID_09CC",
             usb_mi: None,
             description: "punktfunk Virtual DualShock 4",
-        }) {
-            Ok((h, id)) => (Some(h), id),
-            Err(e) => {
-                tracing::warn!(error = %format!("{e:#}"), "SwDeviceCreate failed; DualShock 4 devnode unavailable");
-                (None, None)
-            }
-        };
+        })?; // Propagate, do NOT swallow — see below.
+        let (hsw, instance_id) = (Some(hsw), instance_id);
+        // Swallowing a create failure here (the previous behaviour) latched the pad slot to
+        // `Some(pad)` with no live devnode: `PadSlots::ensure` short-circuits on `is_some()` and
+        // `gate.on_success()` cleared the backoff, so the create-gate that exists precisely to
+        // self-heal a transient PnP failure never retried. The game saw no controller for the whole
+        // session unless the client unplugged the pad. Matches the XUSB sibling, which propagates.
         let _sw = hsw.map(super::gamepad_raii::SwDevice::new);
         // Bounded eager delivery — for the DS4 this is what closes the identity race: the driver
         // must read `device_type = 1` from the delivered DATA section before hidclass asks it for

crates/pf-inject/src/inject/windows/gamepad_windows.rs

@@ -82,12 +82,16 @@ fn create_swdevice(index: u8) -> Result<(HSWDEVICE, Option<String>)> {
     let event = unsafe { CreateEventW(None, true, false, PCWSTR::null())? };
     // `result` starts as E_FAIL, NOT S_OK: if the wait below times out, a zero-initialised HRESULT
     // would read as success and mask the failure (found by the 2026-07 driver-health audit).
-    let mut ctx = SwCreateCtx {
+    // HEAP-allocated for the same reason as the DualSense sibling: the callback writes through this
+    // pointer and SetEvents, and the wait below is bounded — a stack context would be popped while a
+    // late callback still holds it. On the timeout path the box is deliberately leaked and the event
+    // left open so a late write/SetEvent always targets live memory/handle.
+    let ctx = Box::into_raw(Box::new(SwCreateCtx {
         event,
         result: E_FAIL,
         instance_id: [0; 128],
-    };
-    // SAFETY: info + buffers + ctx outlive the call (we wait on the event before returning).
+    }));
+    // SAFETY: info + buffers outlive the call; `ctx` is a live heap allocation outliving every path.
     let hsw = match unsafe {
         SwDeviceCreate(
             w!("punktfunk"),
@@ -95,13 +99,14 @@ fn create_swdevice(index: u8) -> Result<(HSWDEVICE, Option<String>)> {
             &info,
             None,
             Some(sw_create_cb),
-            Some(&mut ctx as *mut SwCreateCtx as *const c_void),
+            Some(ctx as *const c_void),
         )
     } {
         Ok(h) => h,
         Err(e) => {
-            // SAFETY: event is valid.
+            // SAFETY: the call failed, so no callback is pending and `ctx` is ours to reclaim.
             unsafe {
+                drop(Box::from_raw(ctx));
                 let _ = CloseHandle(event);
             }
             return Err(anyhow!("SwDeviceCreate(pf_xusb) failed: {e}"));
@@ -109,17 +114,20 @@ fn create_swdevice(index: u8) -> Result<(HSWDEVICE, Option<String>)> {
     };
     // SAFETY: event valid; block until PnP finishes enumerating, then check the callback result.
     let wait = unsafe { WaitForSingleObject(event, 10_000) };
-    // SAFETY: event is valid.
-    unsafe {
-        let _ = CloseHandle(event);
-    }
     if wait != WAIT_OBJECT_0 {
+        // Timed out — intentionally leak `ctx` and leave `event` open (see above).
         // SAFETY: hsw is the handle SwDeviceCreate returned.
         unsafe { SwDeviceClose(hsw) };
         return Err(anyhow!(
             "SwDeviceCreate(pf_xusb) enumeration callback never fired (10s) — PnP may be wedged"
         ));
     }
+    // The callback ran (it signalled the event), so nothing else will touch `ctx`/`event`.
+    // SAFETY: `ctx` came from `Box::into_raw` and is reclaimed exactly once here.
+    let ctx = unsafe {
+        let _ = CloseHandle(event);
+        Box::from_raw(ctx)
+    };
     if ctx.result.is_err() {
         // SAFETY: hsw is the handle SwDeviceCreate returned.
         unsafe { SwDeviceClose(hsw) };

crates/pf-inject/src/inject/windows/steam_deck_windows.rs

@@ -66,7 +66,7 @@ impl DeckWinPad {
             std::ptr::write_unaligned(base as *mut u32, SHM_MAGIC);
         }
         let inst = format!("pf_deck_{index}");
-        let (hsw, instance_id) = match create_swdevice(&SwDeviceProfile {
+        let (hsw, instance_id) = create_swdevice(&SwDeviceProfile {
             instance: &inst,
             container_tag: 0x5046_4453, // "PFDS"
             container_index: index,
@@ -77,13 +77,8 @@ impl DeckWinPad {
             // spike's run-1 failure).
             usb_mi: Some(2),
             description: "punktfunk Virtual Steam Deck",
-        }) {
-            Ok((h, i)) => (Some(h), i),
-            Err(e) => {
-                tracing::warn!(error = %format!("{e:#}"), "SwDeviceCreate failed; Steam Deck devnode unavailable");
-                (None, None)
-            }
-        };
+        })?; // Propagate — swallowing latched the slot to a pad with no devnode (see the DS4 twin).
+        let (hsw, instance_id) = (Some(hsw), instance_id);
         let _sw = hsw.map(super::gamepad_raii::SwDevice::new);
         // Bounded eager delivery — the driver must read `device_type = 3` before hidclass asks
         // it for descriptors, or the pad would enumerate with the default DualSense identity.