Transplant the hoodie head parts onto the Worker base and put carried props in the hands

TODO.md

@@ -882,8 +882,16 @@ gear) and 5 (head gear on the skull).
 - [x] Worker crown hole on `npc_firefighter`/`npc_crowd_d`: the deleted `Worker_Yellow` hat was
       the crown of the skull. Fixed by keeping it and splitting the material at z 1.65 (crown →
       `hair`, vest stripes → `cloth`).
-- [x] Unibrow on `npc_guard`/`npc_vest`/`npc_crowd_d`: the Worker `Eyebrows` bar is cut out and
-      the hoodie's two brows are transplanted onto the Worker head (`DONOR_BROWS`).
+- [x] Unibrow on `npc_guard`/`npc_vest`/`npc_crowd_d`: the Worker `Eyebrows` bar *and* its
+      oversized eye quads are cut out, and the hoodie's two brows are transplanted onto the Worker
+      head, lifted 18 mm clear of the eye line (`WORKER_HEAD_DONOR`).
+- [x] Worker crown reads as a hard hat: the hoodie's hair is transplanted onto the Worker head and
+      the hard-hat faces above the collar are cut away, so guard/responder/crowd_d have hair.
+- [ ] Worker roles now have **no eyes** (the eye quads were the dark bar that read as a unibrow).
+      Add the `casual` base's smaller eye quads, or a light sclera + pupil, so the face is not
+      brow-and-moustache only.
+- [ ] Hair pokes through the `firefighter_helmet` dome, which now sits under a taller hair shell;
+      re-fit the helmet like the head gear below.
 - [-] Arm/torso intersection on `npc_dress`/`npc_jacket`/`npc_crowd_a`/`npc_crowd_d`: the baked
       rest now aims the upper arm 7° out from vertical. Verified clear on the `casual` base; a
       light clip remains on `worker`, so this needs either a wider angle or a per-base shoulder
@@ -893,9 +901,12 @@ gear) and 5 (head gear on the skull).
 - [ ] Eyes and brows still read as one heavy dark mass at portrait distance (checklist row 3).
 - [ ] Head gear still does not sit on the skull convincingly (row 5): the firefighter helmet brim
       is 1.55× the head width and the cap sits high.
-- [ ] Hand-held gear is still authored for the old hand (row 4): the `npc_vest` clipboard and the
-      `npc_dress` performer sign are oversized, and the sign floats beside the body because
-      `_add_props()` places it at a fixed rig offset instead of on the hand proxy.
+- [x] Carried role props floated beside the body: `_add_props()` placed the performer hat/board
+      and the protester pole/sign at fixed rig offsets. They now ride the hand proxies
+      (`_hand_for()`), and the performer cone was resized from a 0.44 m base to 0.25 m so it sits
+      on the 0.20 m head instead of swallowing it.
+- [ ] Hand-held gear is still authored for the old hand (row 4): the `npc_vest` clipboard is
+      oversized on the shorter Quaternius arm.
 - [-] Build one asset family per commit, AO-baked and re-imported; never run a no-op full-library
       rebuild. Use the concept + vision-judge loop for head/outfit decisions and record model,
       prompt and spend. (Roster family landed in one commit because the three sources share one

assets/models/blender/manifest.json

@@ -640,13 +640,13 @@
       "bounds_godot": {
         "max": [
           0.262,
-          1.863,
+          1.866,
           0.287
         ],
         "min": [
           -0.262,
           -0.004,
-          -0.103
+          -0.087
         ]
       },
       "category": "npc",
@@ -655,11 +655,10 @@
         "skin",
         "cloth",
         "accessory",
-        "hair",
         "Moustache",
-        "Eye",
         "pants",
-        "Brows"
+        "Brows",
+        "hair"
       ],
       "mesh_node": "npc_base",
       "path": "assets/models/blender/npc/npc_crowd_d.glb",
@@ -674,8 +673,8 @@
         "accessory",
         "hair"
       ],
-      "triangles": 5258,
-      "vertices": 10980
+      "triangles": 6176,
+      "vertices": 13074
     },
     "npc_dress": {
       "base": "casual",
@@ -722,13 +721,13 @@
       "bounds_godot": {
         "max": [
           0.262,
-          1.863,
+          1.866,
           0.287
         ],
         "min": [
           -0.262,
           -0.004,
-          -0.103
+          -0.087
         ]
       },
       "category": "npc",
@@ -737,11 +736,10 @@
         "skin",
         "cloth",
         "accessory",
-        "hair",
         "Moustache",
-        "Eye",
         "pants",
-        "Brows"
+        "Brows",
+        "hair"
       ],
       "mesh_node": "npc_base",
       "path": "assets/models/blender/npc/npc_firefighter.glb",
@@ -755,21 +753,21 @@
         "accessory",
         "hair"
       ],
-      "triangles": 5258,
-      "vertices": 10980
+      "triangles": 6176,
+      "vertices": 13074
     },
     "npc_guard": {
       "base": "worker",
       "bounds_godot": {
         "max": [
           0.262,
-          1.863,
+          1.866,
           0.287
         ],
         "min": [
           -0.262,
           -0.004,
-          -0.103
+          -0.087
         ]
       },
       "category": "npc",
@@ -778,11 +776,10 @@
         "skin",
         "cloth",
         "accessory",
-        "hair",
         "Moustache",
-        "Eye",
         "pants",
-        "Brows"
+        "Brows",
+        "hair"
       ],
       "mesh_node": "npc_base",
       "path": "assets/models/blender/npc/npc_guard.glb",
@@ -797,8 +794,8 @@
         "accessory",
         "hair"
       ],
-      "triangles": 5258,
-      "vertices": 10980
+      "triangles": 6176,
+      "vertices": 13074
     },
     "npc_hoodie": {
       "base": "hoodie",
@@ -889,13 +886,13 @@
       "bounds_godot": {
         "max": [
           0.262,
-          1.863,
+          1.866,
           0.287
         ],
         "min": [
           -0.262,
           -0.004,
-          -0.103
+          -0.087
         ]
       },
       "category": "npc",
@@ -905,11 +902,10 @@
         "Worker_Yellow",
         "cloth",
         "accessory",
-        "hair",
         "Moustache",
-        "Eye",
         "pants",
-        "Brows"
+        "Brows",
+        "hair"
       ],
       "mesh_node": "npc_base",
       "path": "assets/models/blender/npc/npc_vest.glb",
@@ -923,8 +919,8 @@
         "accessory",
         "hair"
       ],
-      "triangles": 5258,
-      "vertices": 10980
+      "triangles": 6176,
+      "vertices": 13074
     },
     "palm_tree": {
       "bounds_godot": {

docs/npc-visual-review.md

@@ -68,6 +68,15 @@ not the art, and all three are addressed in the second pass (2026-11-06):
 | `npc_guard`, `npc_vest`, `npc_crowd_d` have one big unibrow | the Worker's `Eyebrows` material is one continuous bar, and no other upstream head has brows that fit this mesh | **replaced** — the bar is cut out and the hoodie's two brows are transplanted onto the Worker head, lifted above the eye quads |
 | `npc_dress`, `npc_jacket`, `npc_crowd_a`, `npc_crowd_d` arms intersect the body | the baked rest aimed the upper arm straight down, which works on the wide bases but not the narrow ones | **reduced** — the arm now rests 7° out from vertical (mesh width 0.180 → 0.220 on `casual`, 0.228 → 0.262 on `hoodie`); a light clip remains on the `worker` bases |
 
+Follow-up pass (same day) went further on the Worker head, which still read as a hard hat under
+the bare tint:
+
+| Finding | Fix |
+| --- | --- |
+| crown still shaped like a hard hat | the hoodie's **hair** is transplanted onto the Worker head and the hat faces above the collar are cut away, so guard/responder/crowd_d have hair |
+| the dark bar was the Worker's *eye* quads, not only the brow bar | the eye quads are removed too; the face now reads brows + moustache |
+| performer cone swallowed the head, and the performer/protester props floated beside the body | `_add_props()` now parents carried props to the hand proxies and the cone shrank from a 0.44 m to a 0.25 m base |
+
 Re-verified after the fix with the sheets below and the vision judge: no holes or missing geometry
 on any of the three Worker-based roles.
 

src/game/npc_avatar.gd

@@ -962,24 +962,33 @@ func _add_props(npc_type: int) -> void:
 		Rules.NpcType.DELIVERY:
 			_add_box_prop(_rig, Vector3(0.34, 0.26, 0.28), Vector3(0.0, 1.02, 0.3), Color(0.55, 0.4, 0.25))
 		Rules.NpcType.PERFORMER:
+			# The cone is sized to the shipped head (0.20 m wide) and sits on the
+			# crown; at the old 0.44 m base it swallowed the whole head.
 			var hat := _material(Color(0.85, 0.2, 0.25))
 			var cone := MeshInstance3D.new()
 			var cm := CylinderMesh.new()
-			cm.top_radius = 0.02
-			cm.bottom_radius = 0.22
-			cm.height = 0.4
+			cm.top_radius = 0.012
+			cm.bottom_radius = 0.125
+			cm.height = 0.24
 			cone.mesh = cm
 			cone.material_override = hat
-			cone.position = Vector3(0, 0.26, 0)
+			cone.position = Vector3(0, 0.15, 0)
 			_head.add_child(cone)
 			# Hat in one hand and a small board in the other: the performer plays
-			# to the sidewalk once at the waypoint.
-			_add_box_prop(_rig, Vector3(0.06, 0.5, 0.06), Vector3(-0.42, 1.3, 0.14), Color(0.45, 0.35, 0.25))
-			_sign_prop = _add_box_prop(_rig, Vector3(0.42, 0.32, 0.03), Vector3(-0.46, 1.6, 0.14), Color(0.95, 0.9, 0.75))
+			# to the sidewalk once at the waypoint. Both ride the hand proxies, so
+			# they follow the arm instead of floating beside the body at a fixed
+			# rig offset (which is what the old -0.46 m placement did).
+			_add_box_prop(_hand_for(0), Vector3(0.05, 0.34, 0.05),
+				HAND_PROP_OFFSET, Color(0.45, 0.35, 0.25))
+			_sign_prop = _add_box_prop(_hand_for(1), Vector3(0.30, 0.24, 0.025),
+				HAND_PROP_OFFSET, Color(0.95, 0.9, 0.75))
 			_sign_prop_base_y = _sign_prop.position.y
 		Rules.NpcType.PROTESTER:
-			_add_box_prop(_rig, Vector3(0.05, 1.2, 0.05), Vector3(0.28, 1.45, 0.18), Color(0.4, 0.36, 0.32))
-			_sign_prop = _add_box_prop(_rig, Vector3(0.5, 0.42, 0.04), Vector3(0.48, 1.55, 0.18), Color(0.93, 0.93, 0.95))
+			# Pole and board ride the carrying hand for the same reason.
+			_add_box_prop(_hand_for(1), Vector3(0.045, 0.95, 0.045),
+				HAND_PROP_OFFSET, Color(0.4, 0.36, 0.32))
+			_sign_prop = _add_box_prop(_hand_for(1), Vector3(0.42, 0.34, 0.035),
+				HAND_PROP_OFFSET + Vector3(0, 0.5, 0), Color(0.93, 0.93, 0.95))
 			_sign_prop_base_y = _sign_prop.position.y
 		Rules.NpcType.TOURIST:
 			_photo_prop = _add_box_prop(_rig, Vector3(0.3, 0.36, 0.14), Vector3(-0.34, 1.15, -0.18), Color(0.25, 0.3, 0.45))
@@ -989,6 +998,19 @@ func _add_props(npc_type: int) -> void:
 		Rules.NpcType.CONFUSED_VISITOR:
 			_add_box_prop(_rig, Vector3(0.3, 0.05, 0.34), Vector3(0, 0.92, 0.06), Color(0.9, 0.88, 0.8))
 
+## Carried role props ride the hand proxy so they follow the arm. The offset is
+## in the hand's local space: the grip sits ~4 cm in front of the wrist origin,
+## the same convention the Blender hand gear uses (`HAND_ITEM_FORWARD`).
+const HAND_PROP_OFFSET := Vector3(0, -0.02, 0.05)
+
+## Hand proxy for a side (0 = the avatar's left, 1 = its right), falling back to
+## the rig when the fallback body has no proxies.
+func _hand_for(side: int) -> Node3D:
+	if side < _hands.size() and _hands[side] != null:
+		return _hands[side]
+	return _rig
+
+
 func _add_box_prop(parent: Node3D, size: Vector3, pos: Vector3, color: Color) -> MeshInstance3D:
 	var mi := MeshInstance3D.new()
 	var mesh := BoxMesh.new()

tools/blender_assets.py

@@ -1504,32 +1504,41 @@ QUATERNIUS_SOURCES = {
                   "Worker_Vest": "cloth",
                   "Worker_Yellow": {"split": True, "z": 1.65,
                                     "above": "hair", "below": "cloth"},
-                  # The bar is deleted in `_transplant_brows()` and replaced by
-                  # the hoodie's two brows; what remains of this material is the
-                  # dark shell over the crown, which follows the hair.
+                  # The bar, the oversized eyes and the hard hat are replaced by
+                  # `_transplant_worker_head()`; those materials are gone by here.
                   "Eyebrows": "hair",
                   "Brows": "keep",
                   "Eye": "keep", "Moustache": "keep"},
-        "donor_brows": True,
+        "donor_head": True,
         "notes": "work shirt (vest geometry) + trousers + hard hat/crown",
     },
 }
 
 
-## The modular Worker's `Eyebrows` material is one continuous bar across the
-## face (the owner reads it as a unibrow) and no other upstream head has brows
-## that fit this head, because the three heads are different meshes. `casual` is
-## the closest sibling, so its two brows are transplanted onto the Worker head
-## and the Worker bar is deleted. Everything else in the pipeline is remapped,
-## never deleted: the Worker's vest *is* its torso and its hard hat *is* the
-## crown of its skull.
-DONOR_BROWS = {"source": "Casual_Hoodie.glb", "material": "Eyebrows",
-               "slot_name": "Brows", "bone": "Head",
-               # The two heads are different meshes: the Worker's eye quads top
-               # out at y 1.709, so the hoodie's brows (1.702-1.717) landed on the
-               # eyes and read as one dark mass. Lift them above the eyes and sink
-               # them into the brow ridge. Blender z = Godot y.
-               "offset": (0.0, 0.0, 0.018)}
+## The modular Worker head has three defects the roster cannot live with, and no
+## other upstream head has parts that fit it directly, because the three heads are
+## different meshes at different detail levels. `casual_hoodie` is the closest
+## sibling, so its brows, eyes and hair are transplanted onto the Worker head:
+##
+##   - `Eyebrows` is one continuous bar across the face (reads as a unibrow);
+##   - `Eye` is two oversized quads that nearly touch (the same dark mass);
+##   - `Worker_Yellow` above the collar is a hard hat that doubles as the skull
+##     crown, so a guard or responder looks like it is wearing a helmet to bed.
+##
+## This is the only place the build removes geometry. Everything else is
+## remapped, because the Worker's vest *is* its torso and its hat *is* its crown.
+WORKER_HEAD_DONOR = {
+    "source": "Casual_Hoodie.glb",
+    # donor material -> contract slot name. The hoodie's eyes are not used: this
+    # head's eye quads are large enough to read as one dark bar, which is the
+    # "unibrow" the owner saw. The brows and hair carry the face instead.
+    "parts": {"Eyebrows": "Brows", "Hair": "hair"},
+    # Lift the brows clear of the eye line (the two heads differ in mesh density).
+    "lift": {"Brows": 0.018},
+    # our material -> height rule for the faces that go away
+    "remove": {"Eyebrows": None, "Eye": None, "Worker_Yellow": 1.60},
+    "bone": "Head",
+}
 
 
 def _base_name(name):
@@ -1538,28 +1547,49 @@ def _base_name(name):
     return head if sep and tail.isdigit() else name
 
 
-def _transplant_brows(obj):
-    """Replace the Worker eyebrow bar with the two brows from the hoodie head."""
-    spec = DONOR_BROWS
-    # Cut our own bar: every `Eyebrows` face below the crown shell.
+def _transplant_worker_head(obj):
+    """Replace the Worker brow bar, eyes and hard hat with the hoodie's head gear."""
+    spec = WORKER_HEAD_DONOR
+    # Resolve the targets before anything is deleted or imported: the material
+    # objects are stable through the join, names are not.
+    targets = {}
+    for name in spec["remove"]:
+        material = next((m for m in obj.data.materials if m and m.name == name), None)
+        if material is not None:
+            targets[material.name] = material
     doomed = []
     for poly in obj.data.polygons:
         material = obj.data.materials[poly.material_index]
-        if material is None or material.name != spec["material"]:
+        if material is None or material.name not in targets:
             continue
-        if _face_centroid(obj, poly)[2] < 1.70:
-            doomed.append(poly.index)
+        limit = spec["remove"].get(material.name)
+        if limit is not None and _face_centroid(obj, poly)[2] <= float(limit):
+            continue
+        doomed.append(poly.index)
     if doomed:
         bm = bmesh.new()
         bm.from_mesh(obj.data)
         bm.faces.ensure_lookup_table()
         bmesh.ops.delete(bm, geom=[bm.faces[i] for i in doomed], context="FACES")
+        loose = [v for v in bm.verts if not v.link_faces]
+        if loose:
+            bmesh.ops.delete(bm, geom=loose, context="VERTS")
         bm.to_mesh(obj.data)
         bm.free()
+        print(f"  removed {len(doomed)} Worker head faces")
+    # Free the slot names so the donor's materials can take them. `pop` removes a
+    # slot by index and repoints the polygons that used it.
+    for index in range(len(obj.data.materials) - 1, -1, -1):
+        slot = obj.data.materials[index]
+        if slot is None or slot.name not in spec["remove"]:
+            continue
+        if any(poly.material_index == index for poly in obj.data.polygons):
+            continue
+        obj.data.materials.pop(index=index)
 
     donor_path = QUATERNIUS_SRC / spec["source"]
     if not donor_path.is_file():
-        print(f"  brows: {donor_path.name} missing, keeping the bar")
+        print(f"  head donor {donor_path.name} missing, Worker head left bare")
         return
     before = set(o.name for o in bpy.context.scene.objects)
     bpy.ops.import_scene.gltf(filepath=str(donor_path))
@@ -1568,16 +1598,14 @@ def _transplant_brows(obj):
     for candidate in added:
         if candidate.type != "MESH":
             continue
-        # A second import of the same pack reuses the material names, so Blender
-        # suffixes them (`Eyebrows.001`); match the base name.
-        keep = [i for i, m in enumerate(candidate.data.materials)
-                if m is not None and _base_name(m.name) == spec["material"]]
-        if not keep:
+        wanted = [i for i, m in enumerate(candidate.data.materials)
+                  if m is not None and _base_name(m.name) in spec["parts"]]
+        if not wanted:
             continue
         bm = bmesh.new()
         bm.from_mesh(candidate.data)
         bm.faces.ensure_lookup_table()
-        drop = [f for f in bm.faces if f.material_index not in keep]
+        drop = [f for f in bm.faces if f.material_index not in wanted]
         if drop:
             bmesh.ops.delete(bm, geom=drop, context="FACES")
         loose = [v for v in bm.verts if not v.link_faces]
@@ -1588,30 +1616,59 @@ def _transplant_brows(obj):
             continue
         bm.to_mesh(candidate.data)
         bm.free()
-        for m in candidate.data.materials:
-            if m is not None and _base_name(m.name) == spec["material"]:
-                m.name = spec["slot_name"]
+        # Collect the kept materials, then remap the faces: clearing the material
+        # list resets every polygon to slot 0.
+        kept = []
+        remap = {}
+        for index, m in enumerate(candidate.data.materials):
+            if m is None:
+                continue
+            slot = spec["parts"].get(_base_name(m.name))
+            if slot is None:
+                continue
+            m.name = slot
+            remap[index] = len(kept)
+            kept.append(m)
+        for slot_name, lift in spec.get("lift", {}).items():
+            local = [i for i, m in enumerate(candidate.data.materials)
+                     if m is not None and m.name == slot_name]
+            if not local:
+                continue
+            bm = bmesh.new()
+            bm.from_mesh(candidate.data)
+            bm.faces.ensure_lookup_table()
+            moved = {v for f in bm.faces if f.material_index in local for v in f.verts}
+            for v in moved:
+                v.co.z += float(lift)
+            bm.to_mesh(candidate.data)
+            bm.free()
+        face_slots = [remap.get(poly.material_index, 0)
+                      for poly in candidate.data.polygons]
+        candidate.data.materials.clear()
+        for m in kept:
+            candidate.data.materials.append(m)
+        for poly, slot in zip(candidate.data.polygons, face_slots):
+            poly.material_index = slot
         donor = candidate
         break
     for extra in added:
         if extra is not donor:
             bpy.data.objects.remove(extra, do_unlink=True)
     if donor is None:
-        print("  brows: donor head not found, keeping the bar")
+        print("  head donor not found, Worker head left bare")
         return
     donor.parent = None
     donor.matrix_world = Matrix.Identity(4)
-    donor.data.transform(Matrix.Translation(spec["offset"]))
-    group = obj.vertex_groups.get(spec["bone"]) or obj.vertex_groups.new(name=spec["bone"])
     for o in bpy.context.selected_objects:
         o.select_set(False)
     obj.select_set(True)
     donor.select_set(True)
     bpy.context.view_layer.objects.active = obj
     bpy.ops.object.join()
-    # The donor's vertices carry no weights; the brows ride the head bone.
+    group = obj.vertex_groups.get(spec["bone"]) or obj.vertex_groups.new(name=spec["bone"])
     group.add([v.index for v in obj.data.vertices if not v.groups], 1.0, "REPLACE")
-    print(f"  transplanted {spec['slot_name']} from {spec['source']}")
+    print(f"  transplanted {', '.join(sorted(spec['parts'].values()))} "
+          f"from {spec['source']}")
 
 
 def _face_centroid(obj, poly):
@@ -1872,8 +1929,8 @@ def _quaternius_tpose_glb(base, overrides):
 
     slots = dict(source["slots"])
     slots.update(overrides)
-    if source.get("donor_brows"):
-        _transplant_brows(obj)
+    if source.get("donor_head"):
+        _transplant_worker_head(obj)
     _quaternius_slot_map(obj, slots)
 
     # Upstream UVs are degenerate (every loop at 0,0), so an AO bake would write