Copy the hoodie eye pair onto the Worker head and lift every hat except the firefighter helmet

TODO.md

@@ -887,14 +887,21 @@ gear) and 5 (head gear on the skull).
       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.
+- [x] Worker roles (vest, firefighter, guard, crowd_d) had **no visible eyes**: the Worker's own
+      quads sit inside the head. The hoodie's eye pair is now transplanted with a 4 mm forward
+      offset, so all four roles show two eyes and two brows (owner request).
+- [x] Owner: every hat/head item moves up. `GEAR_OFFSETS` now lifts the cap, hood and beanie by
+      0.07 m on top of the shared head-gear lift; the firefighter helmet is deliberately unchanged.
 - [x] Worker faces: the dark "unibrow" band turned out to be the **cap brim** sitting on the brow,
       not head geometry. `HEAD_GEAR_LIFT` went 0.07 → 0.103 (the gear is authored around the head
       *centre* at 1.62, the Quaternius head centre is 1.69) and `GEAR_SCALE` grows the cap/hood so
       they clear the 0.228 m hair shell. The cap now reads as a cap and both eyes *and* brows show.
 - [x] Hair poking through head gear: fixed by the same lift + cap/hood scale; the firefighter
       helmet dome covers the hair, and the cap reads as a cap rather than a visor.
-- [ ] The Worker eye quads are still upstream-sized; they read as two dark rectangles rather than
+- [ ] The eyes are single-colour quads on every base; a light sclera + pupil texture on the `Eye`
-      eyes with whites. A light sclera + pupil texture on the `Eye` slot would finish the face.
+      slot would finish the face at portrait distance.
+- [ ] The raised caps now hover slightly above the hair shell with a visible gap; either shrink
+      the hair or fit the cap crown to it.
 - [-] 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

assets/models/blender/manifest.json

@@ -655,11 +655,11 @@
         "skin",
         "cloth",
         "accessory",
-        "hair.001",
+        "Eyebrows",
         "Moustache",
-        "Eye",
         "pants",
         "Brows",
+        "Eye.001",
         "hair"
       ],
       "mesh_node": "npc_base",
@@ -738,11 +738,11 @@
         "skin",
         "cloth",
         "accessory",
-        "hair.001",
+        "Eyebrows",
         "Moustache",
-        "Eye",
         "pants",
         "Brows",
+        "Eye.001",
         "hair"
       ],
       "mesh_node": "npc_base",
@@ -780,11 +780,11 @@
         "skin",
         "cloth",
         "accessory",
-        "hair.001",
+        "Eyebrows",
         "Moustache",
-        "Eye",
         "pants",
         "Brows",
+        "Eye.001",
         "hair"
       ],
       "mesh_node": "npc_base",
@@ -908,11 +908,11 @@
         "Worker_Yellow",
         "cloth",
         "accessory",
-        "hair.001",
+        "Eyebrows",
         "Moustache",
-        "Eye",
         "pants",
         "Brows",
+        "Eye.001",
         "hair"
       ],
       "mesh_node": "npc_base",

src/game/npc_avatar.gd

@@ -181,8 +181,10 @@ const GEAR_OFFSETS := {
 	# The Quaternius head wears a 0.24 m hair shell that stands ~3.5 cm above the
 	# cap crown, so the cap sinks into the hair and only its brim shows. Lift the
 	# cap and hood onto the hair; sunglasses stay at the eye line.
-	"cap": Vector3(0, 0.05, 0),
+	# Owner: every hat and head item moves up; the firefighter helmet keeps its fit.
-	"hood": Vector3(0, 0.03, 0),
+	"cap": Vector3(0, 0.07, 0),
+	"hood": Vector3(0, 0.07, 0),
+	"beanie": Vector3(0, 0.07, 0),
 }
 ## The hat geometry is authored around the 0.315 m procedural head and scaled to
 ## 0.64 in the Blender build to match the 0.20 m Quaternius skull. That fits the
@@ -191,6 +193,7 @@ const GEAR_OFFSETS := {
 const GEAR_SCALE := {
 	"cap": 1.22,
 	"hood": 1.12,
+	"beanie": 1.22,
 }
 ## Hand gear is authored around the wrist proxy. The palm sits ~4 cm in front
 ## of that origin, so without this offset the first phone/flashlight versions

tools/blender_assets.py

@@ -1510,7 +1510,7 @@ QUATERNIUS_SOURCES = {
                                     "above": "hair", "below": "cloth"},
                   # The bar, the oversized eyes and the hard hat are replaced by
                   # `_transplant_worker_head()`; those materials are gone by here.
-                  "Eyebrows": "hair",
+                  "Eyebrows": "keep",
                   "Brows": "keep",
                   "Eye": "keep", "Moustache": "keep"},
         "donor_head": True,
@@ -1534,24 +1534,59 @@ QUATERNIUS_SOURCES = {
 WORKER_HEAD_DONOR = {
     "source": "Casual_Hoodie.glb",
     # donor material -> contract slot name.
-    "parts": {"Eyebrows": "Brows", "Hair": "hair"},
+    "parts": {"Eyebrows": "Brows", "Eye": "Eye", "Hair": "hair"},
     # The three upstream heads carry the same-sized eye quads (x +-0.057), but the
     # Worker's face is flatter, so unchecked they sit proud of the skin and merge
     # into one dark bar -- the "unibrow" the owner saw. Set them back into the
     # socket so the skin crops their edges, and lift the brows clear of them.
-    "offset": {"Brows": (0.0, 0.0, 0.020)},
+    # Brows lift clear of the eye line; the eyes are pushed 4 mm forward so they
+    # clear the Worker's flatter face instead of sinking into it.
+    "offset": {"Brows": (0.0, 0.0, 0.020), "Eye": (0.0, -0.004, 0.0)},
     # Our material -> the height below which its faces go away. `Eyebrows` is the
     # bar *and* the forehead shell, so only the bar is cut: removing the whole
     # material opened the skull and the interior rendered as a black band across
     # the brows. `Eye` goes entirely (its quads read as one dark mass).
-    # `Eye` is deliberately *not* removed: this head has open sockets and the eye
+    # The Worker's own eye quads sit inside the head and never show (the owner
-    # quads are the only thing filling them, so deleting them showed the inside of
+    # reported the Worker roles as eyeless), so they are replaced by the hoodie's
-    # the head as a black band. They stay; the donor brows sit above them.
+    # pair, which is the same geometry the other eight characters use.
-    "remove": {"Eyebrows": 1.715, "Worker_Yellow": 1.60},
+    "remove": {"Eyebrows": 1.715, "Worker_Yellow": 1.60, "Eye": None},
     "bone": "Head",
 }
 
 
+def _purge_unused_materials(obj):
+    """Drop material slots no face uses, so a donor can take the freed name.
+
+    `IDMaterials.pop()` repoints the polygons that used the slot, which corrupted
+    the mesh the first time this was tried; rebuilding the list from the per-face
+    names is explicit and leaves no dangling index.
+    """
+    names = []
+    for poly in obj.data.polygons:
+        material = obj.data.materials[poly.material_index]
+        names.append(material.name if material else "")
+    kept, index_of = [], {}
+    for name in names:
+        if name in index_of:
+            continue
+        source = bpy.data.materials.get(name)
+        if source is None:
+            continue
+        index_of[name] = len(kept)
+        kept.append(source)
+    if len(kept) == len(obj.data.materials):
+        return
+    obj.data.materials.clear()
+    for material in kept:
+        obj.data.materials.append(material)
+    for poly, name in zip(obj.data.polygons, names):
+        poly.material_index = index_of.get(name, 0)
+    # A removed slot leaves its datablock behind with zero users, which still owns
+    # the name and forces the donor's material to `Eye.001`.
+    for material in [m for m in bpy.data.materials if m.users == 0]:
+        bpy.data.materials.remove(material)
+
+
 def _base_name(name):
     """Strip Blender's `.001` duplicate suffix."""
     head, sep, tail = name.rpartition(".")
@@ -1588,6 +1623,8 @@ def _transplant_worker_head(obj):
         bm.to_mesh(obj.data)
         bm.free()
         print(f"  removed {len(doomed)} Worker head faces")
+    _purge_unused_materials(obj)
+
     donor_path = QUATERNIUS_SRC / spec["source"]
     if not donor_path.is_file():
         print(f"  head donor {donor_path.name} missing, Worker head left bare")
@@ -1632,7 +1669,7 @@ def _transplant_worker_head(obj):
             kept.append(m)
         for slot_name, rule in spec.get("narrow", {}).items():
             local = [i for i, m in enumerate(candidate.data.materials)
-                     if m is not None and m.name == slot_name]
+                     if m is not None and _base_name(m.name) == slot_name]
             if not local:
                 continue
             bm = bmesh.new()
@@ -1649,7 +1686,7 @@ def _transplant_worker_head(obj):
 
         for slot_name, offset in spec.get("offset", {}).items():
             local = [i for i, m in enumerate(candidate.data.materials)
-                     if m is not None and m.name == slot_name]
+                     if m is not None and _base_name(m.name) == slot_name]
             if not local:
                 continue
             bm = bmesh.new()
@@ -1684,6 +1721,17 @@ def _transplant_worker_head(obj):
     donor.select_set(True)
     bpy.context.view_layer.objects.active = obj
     bpy.ops.object.join()
+    # The join can leave `Eye.001` next to a zero-user `Eye`; the contract slot
+    # names must be exact because the runtime tints by name.
+    slot_names = {m.name for m in obj.data.materials if m is not None}
+    for material in obj.data.materials:
+        if material is None:
+            continue
+        base = _base_name(material.name)
+        if base != material.name and base not in slot_names:
+            slot_names.discard(material.name)
+            material.name = base
+            slot_names.add(base)
     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 {', '.join(sorted(spec['parts'].values()))} "