3 files changed, 156 insertions, 13 deletions

diff --git a/packages/provider-openai-compat/src/stream.test.ts b/packages/provider-openai-compat/src/stream.test.ts
index ad0f37e..25fd84e 100644
--- a/packages/provider-openai-compat/src/stream.test.ts
+++ b/packages/provider-openai-compat/src/stream.test.ts
@@ -663,9 +663,14 @@ describe("streamChat — record-mode redaction (trace-replay)", () => {
 					headers: { "content-type": "text/event-stream" },
 				}),
 			(fx) => {
-				const redactedHeaders = { ...fx.request.headers };
-				if (redactedHeaders.authorization) {
-					redactedHeaders.authorization = `Bearer ${maskSecret(redactedHeaders.authorization.replace(/^Bearer\s+/, ""))}`;
+				const redactedHeaders: Record<string, string> = {};
+				for (const [key, value] of Object.entries(fx.request.headers)) {
+					if (key.toLowerCase() === "authorization") {
+						const token = value.replace(/^Bearer\s+/i, "");
+						redactedHeaders[key] = `Bearer ${maskSecret(token)}`;
+					} else {
+						redactedHeaders[key] = value;
+					}
 				}
 				capturedFixture = {
 					request: { ...fx.request, headers: redactedHeaders },
@@ -703,14 +708,141 @@ describe("streamChat — record-mode redaction (trace-replay)", () => {
 		expect(serialized).toContain("hi");
 	});
 
+	it("redacts capitalized Authorization header (the real leak casing)", async () => {
+		const apiKey = "sk-LIVEKEY1234567890abcdef";
+		const responseBody = "data: [DONE]\n";
+
+		let capturedFixture: HttpExchangeFixture | undefined;
+		const wrappedFetch = recordFetch(
+			async () =>
+				new Response(responseBody, {
+					status: 200,
+					headers: { "content-type": "text/event-stream" },
+				}),
+			(fx) => {
+				const redactedHeaders: Record<string, string> = {};
+				for (const [key, value] of Object.entries(fx.request.headers)) {
+					if (key.toLowerCase() === "authorization") {
+						const token = value.replace(/^Bearer\s+/i, "");
+						redactedHeaders[key] = `Bearer ${maskSecret(token)}`;
+					} else {
+						redactedHeaders[key] = value;
+					}
+				}
+				capturedFixture = {
+					request: { ...fx.request, headers: redactedHeaders },
+					response: fx.response,
+				};
+			},
+		);
+
+		await wrappedFetch("https://api.example.com/v1/chat/completions", {
+			method: "POST",
+			headers: {
+				"Content-Type": "application/json",
+				Authorization: `Bearer ${apiKey}`,
+			},
+			body: '{"model":"test","messages":[],"stream":true}',
+		});
+
+		assertDefined(capturedFixture);
+		expect(capturedFixture.request.headers.Authorization).toBe("Bearer sk-…redacted…def");
+		expect(capturedFixture.request.headers.Authorization).not.toContain("LIVEKEY1234567890abc");
+
+		const serialized = serializeFixture(capturedFixture);
+		expect(serialized).not.toContain("LIVEKEY1234567890abc");
+		expect(serialized).toContain("Bearer sk-…redacted…def");
+	});
+
+	it("redacts lowercase authorization header", async () => {
+		const apiKey = "sk-abcdefghijkmnop";
+
+		let capturedFixture: HttpExchangeFixture | undefined;
+		const wrappedFetch = recordFetch(
+			async () => new Response("data: [DONE]\n", { status: 200 }),
+			(fx) => {
+				const redactedHeaders: Record<string, string> = {};
+				for (const [key, value] of Object.entries(fx.request.headers)) {
+					if (key.toLowerCase() === "authorization") {
+						const token = value.replace(/^Bearer\s+/i, "");
+						redactedHeaders[key] = `Bearer ${maskSecret(token)}`;
+					} else {
+						redactedHeaders[key] = value;
+					}
+				}
+				capturedFixture = {
+					request: { ...fx.request, headers: redactedHeaders },
+					response: fx.response,
+				};
+			},
+		);
+
+		await wrappedFetch("https://api.example.com/v1/chat/completions", {
+			method: "POST",
+			headers: { authorization: `Bearer ${apiKey}` },
+			body: null,
+		});
+
+		assertDefined(capturedFixture);
+		expect(capturedFixture.request.headers.authorization).toBe("Bearer sk-…redacted…nop");
+		expect(capturedFixture.request.headers.authorization).not.toContain("abcdefghijkm");
+	});
+
+	it("guard: no header named authorization (any case) survives with a raw sk- token", async () => {
+		const apiKey = "sk-REALKEY_1234567890abcdef";
+
+		let capturedFixture: HttpExchangeFixture | undefined;
+		const wrappedFetch = recordFetch(
+			async () => new Response("data: [DONE]\n", { status: 200 }),
+			(fx) => {
+				const redactedHeaders: Record<string, string> = {};
+				for (const [key, value] of Object.entries(fx.request.headers)) {
+					if (key.toLowerCase() === "authorization") {
+						const token = value.replace(/^Bearer\s+/i, "");
+						redactedHeaders[key] = `Bearer ${maskSecret(token)}`;
+					} else {
+						redactedHeaders[key] = value;
+					}
+				}
+				capturedFixture = {
+					request: { ...fx.request, headers: redactedHeaders },
+					response: fx.response,
+				};
+			},
+		);
+
+		await wrappedFetch("https://api.example.com/v1/chat/completions", {
+			method: "POST",
+			headers: { Authorization: `Bearer ${apiKey}` },
+			body: null,
+		});
+
+		assertDefined(capturedFixture);
+		for (const [key, value] of Object.entries(capturedFixture.request.headers)) {
+			if (key.toLowerCase() === "authorization") {
+				expect(value).not.toContain(apiKey);
+				expect(value).not.toMatch(/sk-[A-Za-z0-9]{10,}/);
+			}
+		}
+
+		const serialized = serializeFixture(capturedFixture);
+		expect(serialized).not.toContain(apiKey);
+		expect(serialized).not.toMatch(/sk-[A-Za-z0-9]{10,}/);
+	});
+
 	it("redacts a short API key (≤7 chars → full mask)", async () => {
 		let capturedFixture: HttpExchangeFixture | undefined;
 		const wrappedFetch = recordFetch(
 			async () => new Response("data: [DONE]\n", { status: 200 }),
 			(fx) => {
-				const redactedHeaders = { ...fx.request.headers };
-				if (redactedHeaders.authorization) {
-					redactedHeaders.authorization = `Bearer ${maskSecret(redactedHeaders.authorization.replace(/^Bearer\s+/, ""))}`;
+				const redactedHeaders: Record<string, string> = {};
+				for (const [key, value] of Object.entries(fx.request.headers)) {
+					if (key.toLowerCase() === "authorization") {
+						const token = value.replace(/^Bearer\s+/i, "");
+						redactedHeaders[key] = `Bearer ${maskSecret(token)}`;
+					} else {
+						redactedHeaders[key] = value;
+					}
 				}
 				capturedFixture = {
 					request: { ...fx.request, headers: redactedHeaders },
diff --git a/packages/provider-openai-compat/src/stream.ts b/packages/provider-openai-compat/src/stream.ts
index 7d1f2c8..7cefb25 100644
--- a/packages/provider-openai-compat/src/stream.ts
+++ b/packages/provider-openai-compat/src/stream.ts
@@ -106,9 +106,14 @@ export async function* streamChat(
 			const { recordFetch: rf, saveFixture } = await import("@dispatch/trace-replay");
 			effectiveFetch = rf(effectiveFetch, (fx: HttpExchangeFixture) => {
 				try {
-					const redactedHeaders = { ...fx.request.headers };
-					if (redactedHeaders.authorization) {
-						redactedHeaders.authorization = `Bearer ${maskSecret(redactedHeaders.authorization.replace(/^Bearer\s+/, ""))}`;
+					const redactedHeaders: Record<string, string> = {};
+					for (const [key, value] of Object.entries(fx.request.headers)) {
+						if (key.toLowerCase() === "authorization") {
+							const token = value.replace(/^Bearer\s+/i, "");
+							redactedHeaders[key] = `Bearer ${maskSecret(token)}`;
+						} else {
+							redactedHeaders[key] = value;
+						}
 					}
 					const redacted: HttpExchangeFixture = {
 						request: { ...fx.request, headers: redactedHeaders },
diff --git a/tasks.md b/tasks.md
index e645eca..55ea9ff 100644
--- a/tasks.md
+++ b/tasks.md
@@ -255,10 +255,16 @@ independent of the SQLite trace-store; the lib is redaction-free (caller self-re
   44→48 tests → **331 vitest**, typecheck + biome 0/0. CR: none.
   prompts/provider-trace-replay.md, reports/provider-trace-replay.md.
 - [x] **Build wiring** (orchestrator): root tsconfig ref ✓; provider dep `@dispatch/trace-replay` ✓; `bun install` ✓.
-- [ ] **Live capture** (orchestrator): boot with `DISPATCH_RECORD_FIXTURE` + real key →
-  capture a real flash exchange → secret-free check → re-summon provider to swap the
-  synthetic text-turn fixture for the real one + update expected text (validates our SSE
-  assumptions against reality — D5).
+- [~] **Live capture** (orchestrator): FOUND A BUG (the whole point of D5). The real
+  capture leaked the live API key — record-mode self-redaction MISSED the `Authorization`
+  header (capital A + `Bearer ` prefix; redaction matched lowercase `authorization`).
+  Committed span/journal path is SAFE (journal + trace-DB = ZERO_LEAKS); only the
+  record-mode fixture path leaked, caught PRE-COMMIT (fixture was /tmp-only, scrubbed).
+- [ ] **Record-mode redaction fix** (provider owner): case-insensitive auth-header mask +
+  a test using the REAL `Authorization: Bearer …` representation (must fail before, pass
+  after). prompts/provider-trace-replay-fix.md.
+- [ ] **Re-capture + swap** (orchestrator): after the fix, re-run live capture → secret
+  check → re-summon to commit the clean real fixture + update assertions.
 
 Summons: prompts/phase-a-{kernel-logging,journal-sink}.md;
 reports/phase-a-{kernel-logging,journal-sink}.md.