fix(security): harden owner pair-code against brute-force

- Set express trust proxy=1 so req.ip is the real client (one Dokku
  nginx hop). Drop the X-Forwarded-For fallback — it was client-spoofable.
- Add a global redeem rate limit (30/min across all IPs) so rotating
  proxies can't outpace the per-IP limiter.
- Every failed redeem now decrements life from all active pair codes
  via a shared failures counter. After 5 wrong guesses during a code's
  5-minute TTL, the owner's real code gets burned and they must re-mint.
  This makes the 20-bit entropy of a 6-digit code defensible: an
  attacker doesn't know which code is real and can't probe long enough
  to find it before triggering the burn.

server/routes/owner.ts

@@ -15,24 +15,40 @@ const router = Router();
 // ─── Device pair-code store (in-memory) ─────────────────────────────────────
 // 6-digit short codes minted by an already-logged-in owner session so a
 // touchscreen device (the Tesla in-car browser) can log in without retyping
-// the long OWNER_SECRET. 5-minute TTL, single use, rate-limited.
+// the long OWNER_SECRET.
+//
+// Defence in depth — 6 digits is only ~20 bits of entropy on its own:
+//   - single-use (delete on success)
+//   - 5-minute TTL
+//   - per-code failure cap: a code self-destructs after 5 wrong guesses
+//   - per-IP rate limit (req.ip via 'trust proxy' = 1, not spoofable)
+//   - global rate limit across all IPs (defeats parallel-IP brute force)
 const PAIR_CODE_TTL_MS = 5 * 60 * 1000;
-const pairCodes = new Map<string, { expiresAt: number }>();
-// IP → recent redeem attempt timestamps (oldest first).
-const redeemAttempts = new Map<string, number[]>();
-const MAX_REDEEM_PER_MIN = 8;
+const MAX_FAILED_PER_CODE = 5;
+const MAX_REDEEM_PER_IP_PER_MIN = 8;
+const MAX_REDEEM_GLOBAL_PER_MIN = 30;
+
+interface PairCodeEntry { expiresAt: number; failures: number }
+const pairCodes = new Map<string, PairCodeEntry>();
+const redeemAttemptsByIp = new Map<string, number[]>();
+let redeemAttemptsGlobal: number[] = [];
 
 function cleanPairCodes(): void {
   const now = Date.now();
   for (const [k, v] of pairCodes) if (v.expiresAt < now) pairCodes.delete(k);
 }
 
-function rateLimited(ip: string): boolean {
+function recordAttempt(ip: string): { ipLimited: boolean; globalLimited: boolean } {
   const now = Date.now();
-  const arr = (redeemAttempts.get(ip) || []).filter(t => now - t < 60_000);
-  arr.push(now);
-  redeemAttempts.set(ip, arr);
-  return arr.length > MAX_REDEEM_PER_MIN;
+  const ipArr = (redeemAttemptsByIp.get(ip) || []).filter(t => now - t < 60_000);
+  ipArr.push(now);
+  redeemAttemptsByIp.set(ip, ipArr);
+  redeemAttemptsGlobal = redeemAttemptsGlobal.filter(t => now - t < 60_000);
+  redeemAttemptsGlobal.push(now);
+  return {
+    ipLimited: ipArr.length > MAX_REDEEM_PER_IP_PER_MIN,
+    globalLimited: redeemAttemptsGlobal.length > MAX_REDEEM_GLOBAL_PER_MIN,
+  };
 }
 
 router.get('/api/auth/owner/status', (req, res) => {
@@ -77,28 +93,49 @@ router.post('/api/auth/owner/pair-code', (req, res) => {
   do {
     code = String(crypto.randomInt(100_000, 1_000_000));
   } while (pairCodes.has(code));
-  pairCodes.set(code, { expiresAt: Date.now() + PAIR_CODE_TTL_MS });
+  pairCodes.set(code, { expiresAt: Date.now() + PAIR_CODE_TTL_MS, failures: 0 });
   res.json({ ok: true, code, expiresInS: Math.floor(PAIR_CODE_TTL_MS / 1000) });
 });
 
+// Mark a failed redeem against every currently-active code. With 6-digit
+// entropy, an attacker brute-forcing the keyspace doesn't know which code
+// the owner minted — but every wrong guess they make burns life from the
+// real code. Five misses during a code's TTL is enough to invalidate it
+// and force the owner to re-mint, which defeats parallel-IP brute force.
+function markFailureAgainstActiveCodes(): void {
+  for (const [code, entry] of pairCodes) {
+    entry.failures += 1;
+    if (entry.failures > MAX_FAILED_PER_CODE) {
+      pairCodes.delete(code);
+    }
+  }
+}
+
 // ─── Pair code: redeem on a new device ──────────────────────────────────────
 router.post('/api/auth/owner/pair-redeem', (req, res) => {
-  const ip = (req.ip || (req.headers['x-forwarded-for'] as string) || 'unknown').toString();
-  if (rateLimited(ip)) {
+  // req.ip is trustworthy because we set 'trust proxy' = 1 in server/index.ts.
+  // Do NOT fall back to the X-Forwarded-For header — it's client-controlled.
+  const ip = req.ip || 'unknown';
+  const { ipLimited, globalLimited } = recordAttempt(ip);
+  if (ipLimited || globalLimited) {
+    log.warn({ ip, ipLimited, globalLimited }, 'pair-redeem rate limited');
     res.status(429).json({ ok: false, reason: 'rate_limited' });
     return;
   }
   const { code } = (req.body || {}) as { code?: unknown };
   if (typeof code !== 'string' || !/^\d{6}$/.test(code)) {
+    markFailureAgainstActiveCodes();
     res.status(400).json({ ok: false, reason: 'bad_code' });
     return;
   }
   cleanPairCodes();
   const entry = pairCodes.get(code);
   if (!entry) {
+    markFailureAgainstActiveCodes();
     res.status(401).json({ ok: false, reason: 'invalid_or_expired' });
     return;
   }
+  // Success: consume the code, set the cookie.
   pairCodes.delete(code);
   setOwnerCookie(res);
   log.info({ ip }, 'Device paired via owner pair code');