fix: --project/--exclude are ignored by the durable headline totals

[GodCC6]

Summary

• --project / --exclude were ignored by the durable headline: buildDurablePeriod slices the cache-sourced days to the requested provider but never to the requested project, so the Overview total counted excluded projects while By Project / By Activity / By Model (built from the name-filtered live parse) left them out.
• Adds sliceDayToProject, the project-level counterpart of sliceDayToProvider, so cost / calls / sessions / savings are sliced out of the per-project day stats the cache has carried since v15 — exact, and still including days whose session files have expired.
• Fields the cache has no per-project split for are handled explicitly rather than attributed to the filtered projects; a day that cannot be attributed at all is reported as unattributedCostUSD and footnoted, never silently folded in.

Testing

• I have tested this locally against real data (not just unit tests)
• npm test passes
• npm run build succeeds

npm test: 2,492 passed, 5 failed — all 5 fail identically on a clean checkout of this PR's base commit, so none are mine: cache-refresh-lock (fence/heartbeat), parser (copilot file-purge, orphan fingerprint), sharing/connect-timeout, and cli-durable-totals "resolves provider filters identically". That last one fails on main because parseAllSessions returns nothing for a today-only range once the on-disk session cache is warm — unrelated to this change, but you may want a separate look. npx tsc --noEmit is clean.

Repro

npx codeburn report -p week \
  --exclude Projects/ai-invest-copilot \
  --exclude writing/publishing/automation \
  --exclude Projects/novel-writing-publish \
  --exclude ai/invest/copilot

Overview reported $7,962.65 while every By Project row summed to ~$5,503.70 — a ~$2,458.95 gap, exactly the excluded projects' spend. By Activity and By Model both summed into the same $5,500–5,600 band, so the detail panels agreed with each other and only the headline was off.

Measured on the same corpus with --format json (the -p week window had moved on by then, so absolute figures differ slightly):

	Overview total	By Project sum	gap
before	$8,004.30	$5,575.45	+$2,428.85
after	$5,535.12	$5,574.74	−$39.62
unfiltered control (after)	$8,095.19	$8,166.12	−$70.93

Calls were off by the same mechanism: 84,458 → 56,492. The small residual is not from this change — the unfiltered control shows a larger pre-existing divergence, because the durable path counts whole local days out of the cache while the live parse filters turns by exact timestamp, so the two differ at a rolling range's boundary.

Footnote behaviour on the same real cache (15 of 93 days predate the per-project split):

Bottom line: Lifetime totals $15,148.50 across 18,512,251,593 tokens, mostly claude / gpt-5.6-sol.
  includes $27.26 preserved from expired session logs
  excludes $2,214.63 from days with no per-project history

Root cause

buildDurablePeriod() unions two sources: today, via fp(await parseAllSessions(...)) where fp = filterProjectsByName(...) — filtered — and history, via getDaysInRange(cache, ...) merged by unionDaysForPeriod() — never project-filtered. Provider filtering did slice the historical days (pf === 'all' ? allDays : allDays.map(d => sliceDayToProvider(d, pf))); there was simply no project-level counterpart. buildJsonReport() reads totalCostUSD straight from durable.data, which is why Overview overstated, while By Project reads the correctly-filtered durable.liveProjects.

Filter matching mirrors filterProjectsByName exactly — case-insensitive substring against the project name or its path, include then exclude — so a filter selects the same projects whether it resolves against a fresh parse or the day cache. Provider slices carry their own projects split, so they are sliced too and --provider X --exclude Y stays consistent with the day-level slice.

Known limitation — your call

ProjectDayStats is { cost, calls, savingsUSD, sessions, path? }: there is no per-project split for tokens, models or categories. I picked the option that never reports another project's numbers as the filtered projects', but the alternative is defensible and I'm happy to switch:

• tokens / models / categories now come from the (already project-filtered) live parse when a project filter is active. Exact for every surviving session and consistent with the By Model / By Activity panels that read the same parse — but bounded by source retention, so a project-filtered lifetime query no longer counts tokens from days whose logs are gone. Keeping the day-level values instead would leave those fields overstating by exactly the excluded projects.
• days (or provider slices) carried from before v15 have no project split at all, so they cannot be attributed and contribute nothing; their cost comes back as unattributedCostUSD and the overview footnotes it. Folding them in would keep --project X claiming spend that provably isn't X's, so I chose a stated shortfall over a silent overstatement — but that trades against the never-lose-history invariant, so say the word if you'd rather keep them.

A refinement I deliberately left out: on the 13 days in my cache where the day has a split but one provider slice doesn't, the missing slice is derivable as day.projects minus the other slices' projects. That assumes the merged day is internally consistent and a clamped subtraction would fail silently when it isn't, so it seemed better as a follow-up than as part of a correctness fix.

Adjacent, not fixed here

The menubar / status provider list has the same root cause: usage-aggregator.ts:632-635 builds unfilteredProviderDays from getDaysInRange(cache, ...) (unfiltered) plus getTodayAllDays() (filtered), so per-provider costs still ignore --project/--exclude for historical days. I left it out because narrowing it also changes which providers appear in the list at all, which felt like your call rather than mine. Happy to do it here or in a follow-up.

Tests

tests/project-filter-durable-totals.test.ts, 11 cases, the failing-first ones written before the fix: exclude and include filters against a two-project carried day, path matching, a fully-excluded day, project-underneath-provider, and the two pre-v15 fallbacks plus the overview footnote. Two are invariant guards that hold before and after the change rather than red-first tests — the unfiltered headline being byte-for-byte what it was, and the menubar payload staying in step with the report under a project filter.

Filed as #865, which also carries the two policy questions above in case you'd rather settle them there.

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