Move caller dialog to Sonnet 4.6, add SearXNG for Devon, and fix stale model ids

Working-tree changes that had accumulated without being committed. The test
updates matter most: tests/test_caller_gen.py was left behind when caller_gen
started requiring voice and age in regulars_included, so the committed tree had
a failing suite that only passed locally.

- Caller dialog moves from Haiku 4.5 to Sonnet 4.6 (~$1/show to ~$3-4/show)
- Grok pinned to x-ai/grok-4.3; grok-4, grok-4-fast and grok-4.1-fast were
  retired from OpenRouter, and llm.py swallows the 404 and returns empty text,
  so a retired id makes callers go silent with nothing in the logs
- Devon's web_search now runs against SearXNG on the NAS
- Assorted TTS, audio, news, cost tracker and control-panel changes
- CLAUDE.md updated to match

Co-Authored-By: Claude Opus 5 <noreply@anthropic.com>

tests/test_caller_gen.py

@@ -63,8 +63,15 @@ def test_resolve_voice_case_insensitive():
 def test_resolve_voice_falls_back_when_no_match():
     from backend.services.caller_gen import resolve_voice
     roster = ["Marcus", "Dennis"]
-    # Deterministic fallback: return first from roster
-    assert resolve_voice("Santiago", roster) == "Marcus"
+    # Random fallback, so hallucinated voices don't all collapse onto roster[0]
+    assert resolve_voice("Santiago", roster) in roster
+
+
+def test_resolve_voice_fallback_spreads_across_roster():
+    from backend.services.caller_gen import resolve_voice
+    roster = ["Marcus", "Dennis", "Priya", "Edward"]
+    picked = {resolve_voice("Santiago", roster) for _ in range(60)}
+    assert len(picked) > 1, "fallback collapsed onto a single voice"
 
 
 def test_resolve_voice_empty_suggestion_falls_back():
@@ -103,7 +110,7 @@ def test_build_batch_prompt_includes_silas_lore_when_present():
         "weather": "...",
         "headlines": [],
         "recent_caller_summaries": [],
-        "regulars_included": [{"name": "Silas", "lore": "Silas leads a small desert cult...", "arc_state": "seeking new members"}],
+        "regulars_included": [{"name": "Silas", "voice": "Sebastian", "age": 52, "lore": "Silas leads a small desert cult...", "arc_state": "seeking new members"}],
         "caller_count": 12,
         "voice_roster": ["Marcus"],
     }

tests/test_caller_prompt.py

@@ -22,4 +22,36 @@ def test_prompt_includes_identity_and_situation():
     assert "NEVER use asterisks" in prompt
     assert "NEVER use parenthetical stage directions" in prompt
     assert "Mix short punchy replies with longer ones" in prompt
+    assert "YOU CAN BE MOVED" in prompt
+    assert "NEVER restate the same dilemma" in prompt
     assert len(prompt) < 3500
+
+
+def test_prompt_includes_opening_line():
+    caller = {
+        "name": "Tina",
+        "identity": "A nurse who just got off a 16-hour shift",
+        "situation": "Found her ex's wedding invitation in her mailbox",
+        "reason_calling": "She's not sure if she should go",
+        "secret_want": "Wants someone to tell her she's over him",
+        "opening_line": "Luke, I literally just got home from work and there's this gold envelope sitting on my kitchen counter.",
+        "specific_details": ["invitation was hand-addressed", "wedding is in two weeks"],
+    }
+    prompt = get_caller_prompt(caller)
+    assert "gold envelope" in prompt
+    assert "FIRST message" in prompt
+    assert "listening for" in prompt.lower() or "been listening" in prompt.lower()
+
+
+def test_prompt_without_opening_line():
+    caller = {
+        "name": "Ray",
+        "identity": "A retired mechanic",
+        "situation": "Neighbor's dog dug up something weird",
+        "reason_calling": "He thinks it might be human bones",
+        "secret_want": "Doesn't want to call the cops on his neighbor",
+        "specific_details": ["bones were wrapped in a tarp"],
+    }
+    prompt = get_caller_prompt(caller)
+    assert "FIRST message" not in prompt
+    assert "planned opening" not in prompt.lower()

tests/test_session.py

@@ -64,6 +64,49 @@ def test_session_get_show_history_summary():
     assert "EARLIER IN THE SHOW" in summary
 
 
+def test_show_history_reactions_constant_is_usable():
+    from backend.main import SHOW_HISTORY_REACTIONS
+
+    assert SHOW_HISTORY_REACTIONS, "generic reaction pool must not be empty"
+    assert all(isinstance(r, str) and r.strip() for r in SHOW_HISTORY_REACTIONS)
+    # Each one is interpolated as "...and you {reaction}." so it must not
+    # carry its own leading/trailing punctuation or an unfilled placeholder.
+    for r in SHOW_HISTORY_REACTIONS:
+        assert not r.endswith("."), r
+        assert "{" not in r, r
+
+
+def test_build_specific_reaction_falls_back_when_record_has_no_details():
+    """A CallRecord with neither key_details nor situation_summary hits the
+    generic branch — this used to raise NameError mid-show."""
+    from backend.main import SHOW_HISTORY_REACTIONS
+
+    s = Session()
+    bare = CallRecord(
+        caller_type="ai", caller_name="Jasmine",
+        summary="Talked about her boss", transcript=[],
+    )
+    reaction = s._build_specific_reaction({}, bare)
+    assert reaction in SHOW_HISTORY_REACTIONS
+
+
+def test_get_show_history_never_raises_when_reaction_branch_fires(monkeypatch):
+    """Force the reaction branch every time so the fallback path is covered
+    deterministically rather than at its ~15% random rate."""
+    import backend.main as main
+
+    monkeypatch.setattr(main.random, "random", lambda: 0.0)
+
+    s = Session()
+    s.call_history.append(CallRecord(
+        caller_type="real", caller_name="Dave",
+        summary="Called about his wife leaving", transcript=[],
+    ))
+    summary = s.get_show_history()
+    assert "DAVE" in summary
+    assert "and you " in summary
+
+
 def test_session_reset_clears_history():
     s = Session()
     s.call_history.append(CallRecord(