Verify NPC headgear clearance after the face pass

MEMORY.md

@@ -96,6 +96,10 @@ Session memory for durable decisions, state, and gotchas. Keep concise, remove o
   0.150→0.146, chest 0.170→0.168, upper chest 0.172→0.170. This is a subtle shirt taper, not a
   skeleton change; all proportions pass and `sheet_npc_baseline_compare-torso.jpg` records it.
   Max character is 4,754 tris / 4,584 verts.
+- **NPC headgear clearance (0.9.4, 2026-11-02):** after the face-detail pass, the 96
+  final-context frames confirm the cap, firefighter helmet, hood and sunglasses clear the refined
+  brow/eyes; `blender_assets.py fit` stays clean, so no gear was rebuilt. The broad helmet brim is
+  intentional turnout language, not a fit failure.
 - **NPC face-detail pass (0.9.4, 2026-11-02):** Nose tip radius reduced to 0.022 with ala wings,
   the two dark lip boxes became one shallow `Mouth` sphere (two blobs read as a moustache), and the
   ears gained a dark `EarInner` concha. All eight rebuilt; current counts are 4,226–5,218 tris /

TODO.md

@@ -115,8 +115,9 @@ and equipment fit.
       rebuilt. `sheet_npc_baseline_compare-face-detail.jpg`.)
 - [ ] Audit hair caps, fringes, side locks, buns and beard silhouettes for gaps, intersections and
       obvious scalp seams; keep hair color in the tintable slot.
-- [ ] Verify hats/hoods/sunglasses/helmets still clear the refined brow, ears and hair; update gear
+- [x] Verify hats/hoods/sunglasses/helmets still clear the refined brow, ears and hair; update gear
-      fit measurements and rebuild any affected gear.
+      fit measurements and rebuild any affected gear. (Final-context 96-frame review: cap, helmet,
+      hood and sunglasses clear the eyes; `blender_assets.py fit` clean; no rebuild needed.)
 - [ ] Check face readability under day, evening and LATE lighting and at the portrait capture’s
       shallow depth of field.
 

docs/development-status.md

@@ -44,6 +44,7 @@ Implemented so far:
 - NPC torso/hip transition (0.9.4 work): the pelvis and chest are slightly wider than the waist, giving shirts and jackets a readable taper into the hips without changing the build multipliers or the skeleton. The comparison is `sheet_npc_baseline_compare-torso.jpg`.
 - NPC mesh budget (0.9.4 work): the eight library variants now have an 8,000-triangle / 8,000-glTF-vertex cap (up from 6,000/5,000); the `npc_base` fallback remains 6,000/4,000. Current characters measure 4,226–5,218 triangles and 4,119–5,240 vertices.
 - NPC face-detail pass (0.9.4 work): ala wings and a smaller nose bridge/tip, one rounded mouth slot, and a darker ear concha; all eight rebuilt. The comparison is `sheet_npc_baseline_compare-face-detail.jpg`.
+- NPC headgear clearance (0.9.4 work): the 96-frame final-context review after the face-detail pass confirms the cap, firefighter helmet, hood and sunglasses clear the refined brow and eyes; no gear rebuild was needed.
 - NPC hand pass (0.9.4 work): wider, shallower palms; four two-segment bent fingers with rounded tips and a separate bent thumb; optional `--view=hand` capture at 0.80 m. The hand comparison is `sheet_npc_hands_compare.jpg`; item grip offsets remain open.
 - NPC proportion audit (0.9.4 work): `tools/npc_proportions.py` measures all eight GLBs against a stylized height/head/shoulder/hip/torso/leg/arm/foot guide. All variants pass; the head and broad-build silhouettes are the nearest upper bounds. Results are in [`npc-proportion-audit.md`](npc-proportion-audit.md).
 - NPC P1 portrait fixes (0.9.4 work): tourists now hide their photo-pose camera bag outside `photo`/`film` poses, removing the duplicate-backpack silhouette; the backpack gear was rebuilt with flattened, forward chest straps and a fresh AO map. The before/after sheet is [`blender_previews/sheet_npc_baseline_compare-p1.jpg`](blender_previews/sheet_npc_baseline_compare-p1.jpg); the face and remaining clothing/hand work stay open.

docs/npc-visual-review.md

@@ -169,10 +169,11 @@ The refit backpack measures 380 triangles / 406 vertices.
 6. **Shoes are simple blocks.** They are grounded, but the toe/heel silhouette
    is minimal; the responder and firefighter footwear should remain distinct
    after any refinement.
-7. **Headgear scale needs a visual, not just numeric, check.** The cap and
+7. **Headgear scale and clearance. Checked 2026-11-02.** The cap and helmet
-   helmet width ratios are 1.067 and 1.651; those are expected for headgear, but
+   width ratios are 1.067 and 1.651; those are expected for headgear. Final-context
-   the brim/ear clearance and the helmet's relationship to the head still need a
+   portraits confirm the cap, firefighter helmet, hood and sunglasses clear the
-   face-on check.
+   refined brow/eyes, and the helmet brim still reads as deliberate turnout gear.
+   No gear rebuild was needed.
 8. **Performer props dominate the silhouette.** The red cone hat and the
    primitive sign are intentionally large stage props, but they should be
    checked during the pose pass so they do not read as head/body geometry.