diff --git a/bin/autoforge.js b/bin/autoforge.js
old mode 100644
new mode 100755
diff --git a/server/routers/assistant_chat.py b/server/routers/assistant_chat.py
index ceae8bd2..69fe9672 100644
--- a/server/routers/assistant_chat.py
+++ b/server/routers/assistant_chat.py
@@ -217,20 +217,26 @@ async def assistant_chat_websocket(websocket: WebSocket, project_name: str):
     - {"type": "error", "content": "..."} - Error message
     - {"type": "pong"} - Keep-alive pong
     """
-    if not validate_project_name(project_name):
+    # Always accept WebSocket first to avoid opaque 403 errors
+    await websocket.accept()
+
+    try:
+        project_name = validate_project_name(project_name)
+    except HTTPException:
+        await websocket.send_json({"type": "error", "content": "Invalid project name"})
         await websocket.close(code=4000, reason="Invalid project name")
         return
 
     project_dir = _get_project_path(project_name)
     if not project_dir:
+        await websocket.send_json({"type": "error", "content": "Project not found in registry"})
         await websocket.close(code=4004, reason="Project not found in registry")
         return
 
     if not project_dir.exists():
+        await websocket.send_json({"type": "error", "content": "Project directory not found"})
         await websocket.close(code=4004, reason="Project directory not found")
         return
-
-    await websocket.accept()
     logger.info(f"Assistant WebSocket connected for project: {project_name}")
 
     session: Optional[AssistantChatSession] = None
diff --git a/server/routers/expand_project.py b/server/routers/expand_project.py
index 5b55824e..d680b952 100644
--- a/server/routers/expand_project.py
+++ b/server/routers/expand_project.py
@@ -104,19 +104,26 @@ async def expand_project_websocket(websocket: WebSocket, project_name: str):
     - {"type": "error", "content": "..."} - Error message
     - {"type": "pong"} - Keep-alive pong
     """
+    # Always accept the WebSocket first to avoid opaque 403 errors.
+    # Starlette returns 403 if we close before accepting.
+    await websocket.accept()
+
     try:
         project_name = validate_project_name(project_name)
     except HTTPException:
+        await websocket.send_json({"type": "error", "content": "Invalid project name"})
         await websocket.close(code=4000, reason="Invalid project name")
         return
 
     # Look up project directory from registry
     project_dir = _get_project_path(project_name)
     if not project_dir:
+        await websocket.send_json({"type": "error", "content": "Project not found in registry"})
         await websocket.close(code=4004, reason="Project not found in registry")
         return
 
     if not project_dir.exists():
+        await websocket.send_json({"type": "error", "content": "Project directory not found"})
         await websocket.close(code=4004, reason="Project directory not found")
         return
 
@@ -124,11 +131,10 @@ async def expand_project_websocket(websocket: WebSocket, project_name: str):
     from autoforge_paths import get_prompts_dir
     spec_path = get_prompts_dir(project_dir) / "app_spec.txt"
     if not spec_path.exists():
+        await websocket.send_json({"type": "error", "content": "Project has no spec. Create a spec first before expanding."})
         await websocket.close(code=4004, reason="Project has no spec. Create spec first.")
         return
 
-    await websocket.accept()
-
     session: Optional[ExpandChatSession] = None
 
     try:
diff --git a/server/routers/spec_creation.py b/server/routers/spec_creation.py
index cb7263ce..ebe5c5bd 100644
--- a/server/routers/spec_creation.py
+++ b/server/routers/spec_creation.py
@@ -166,22 +166,28 @@ async def spec_chat_websocket(websocket: WebSocket, project_name: str):
     - {"type": "error", "content": "..."} - Error message
     - {"type": "pong"} - Keep-alive pong
     """
-    if not validate_project_name(project_name):
+    # Always accept WebSocket first to avoid opaque 403 errors
+    await websocket.accept()
+
+    try:
+        project_name = validate_project_name(project_name)
+    except HTTPException:
+        await websocket.send_json({"type": "error", "content": "Invalid project name"})
         await websocket.close(code=4000, reason="Invalid project name")
         return
 
     # Look up project directory from registry
     project_dir = _get_project_path(project_name)
     if not project_dir:
+        await websocket.send_json({"type": "error", "content": "Project not found in registry"})
         await websocket.close(code=4004, reason="Project not found in registry")
         return
 
     if not project_dir.exists():
+        await websocket.send_json({"type": "error", "content": "Project directory not found"})
         await websocket.close(code=4004, reason="Project directory not found")
         return
 
-    await websocket.accept()
-
     session: Optional[SpecChatSession] = None
 
     try:
diff --git a/server/routers/terminal.py b/server/routers/terminal.py
index a53b9abe..6845a27e 100644
--- a/server/routers/terminal.py
+++ b/server/routers/terminal.py
@@ -221,8 +221,12 @@ async def terminal_websocket(websocket: WebSocket, project_name: str, terminal_i
     - {"type": "pong"} - Keep-alive response
     - {"type": "error", "message": "..."} - Error message
     """
+    # Always accept WebSocket first to avoid opaque 403 errors
+    await websocket.accept()
+
     # Validate project name
     if not validate_project_name(project_name):
+        await websocket.send_json({"type": "error", "message": "Invalid project name"})
         await websocket.close(
             code=TerminalCloseCode.INVALID_PROJECT_NAME, reason="Invalid project name"
         )
@@ -230,6 +234,7 @@ async def terminal_websocket(websocket: WebSocket, project_name: str, terminal_i
 
     # Validate terminal ID
     if not validate_terminal_id(terminal_id):
+        await websocket.send_json({"type": "error", "message": "Invalid terminal ID"})
         await websocket.close(
             code=TerminalCloseCode.INVALID_PROJECT_NAME, reason="Invalid terminal ID"
         )
@@ -238,6 +243,7 @@ async def terminal_websocket(websocket: WebSocket, project_name: str, terminal_i
     # Look up project directory from registry
     project_dir = _get_project_path(project_name)
     if not project_dir:
+        await websocket.send_json({"type": "error", "message": "Project not found in registry"})
         await websocket.close(
             code=TerminalCloseCode.PROJECT_NOT_FOUND,
             reason="Project not found in registry",
@@ -245,6 +251,7 @@ async def terminal_websocket(websocket: WebSocket, project_name: str, terminal_i
         return
 
     if not project_dir.exists():
+        await websocket.send_json({"type": "error", "message": "Project directory not found"})
         await websocket.close(
             code=TerminalCloseCode.PROJECT_NOT_FOUND,
             reason="Project directory not found",
@@ -254,14 +261,13 @@ async def terminal_websocket(websocket: WebSocket, project_name: str, terminal_i
     # Verify terminal exists in metadata
     terminal_info = get_terminal_info(project_name, terminal_id)
     if not terminal_info:
+        await websocket.send_json({"type": "error", "message": "Terminal not found"})
         await websocket.close(
             code=TerminalCloseCode.PROJECT_NOT_FOUND,
             reason="Terminal not found",
         )
         return
 
-    await websocket.accept()
-
     # Get or create terminal session for this project/terminal
     session = get_terminal_session(project_name, project_dir, terminal_id)
 
diff --git a/server/websocket.py b/server/websocket.py
index dfb4dee7..e6600643 100644
--- a/server/websocket.py
+++ b/server/websocket.py
@@ -640,9 +640,7 @@ def __init__(self):
         self._lock = asyncio.Lock()
 
     async def connect(self, websocket: WebSocket, project_name: str):
-        """Accept a WebSocket connection for a project."""
-        await websocket.accept()
-
+        """Register a WebSocket connection for a project (must already be accepted)."""
         async with self._lock:
             if project_name not in self.active_connections:
                 self.active_connections[project_name] = set()
@@ -727,16 +725,22 @@ async def project_websocket(websocket: WebSocket, project_name: str):
     - Agent status changes
     - Agent stdout/stderr lines
     """
+    # Always accept WebSocket first to avoid opaque 403 errors
+    await websocket.accept()
+
     if not validate_project_name(project_name):
+        await websocket.send_json({"type": "error", "content": "Invalid project name"})
         await websocket.close(code=4000, reason="Invalid project name")
         return
 
     project_dir = _get_project_path(project_name)
     if not project_dir:
+        await websocket.send_json({"type": "error", "content": "Project not found in registry"})
         await websocket.close(code=4004, reason="Project not found in registry")
         return
 
     if not project_dir.exists():
+        await websocket.send_json({"type": "error", "content": "Project directory not found"})
         await websocket.close(code=4004, reason="Project directory not found")
         return
 
@@ -879,8 +883,7 @@ async def on_dev_status_change(status: str):
                 break
             except json.JSONDecodeError:
                 logger.warning(f"Invalid JSON from WebSocket: {data[:100] if data else 'empty'}")
-            except Exception as e:
-                logger.warning(f"WebSocket error: {e}")
+            except Exception:
                 break
 
     finally:
diff --git a/ui/src/App.tsx b/ui/src/App.tsx
index 8a185a27..9e1b6e52 100644
--- a/ui/src/App.tsx
+++ b/ui/src/App.tsx
@@ -178,8 +178,8 @@ function App() {
         setShowAddFeature(true)
       }
 
-      // E : Expand project with AI (when project selected and has features)
-      if ((e.key === 'e' || e.key === 'E') && selectedProject && features &&
+      // E : Expand project with AI (when project selected, has spec and has features)
+      if ((e.key === 'e' || e.key === 'E') && selectedProject && hasSpec && features &&
           (features.pending.length + features.in_progress.length + features.done.length) > 0) {
         e.preventDefault()
         setShowExpandProject(true)
@@ -239,7 +239,7 @@ function App() {
 
     window.addEventListener('keydown', handleKeyDown)
     return () => window.removeEventListener('keydown', handleKeyDown)
-  }, [selectedProject, showAddFeature, showExpandProject, selectedFeature, debugOpen, debugActiveTab, assistantOpen, features, showSettings, showKeyboardHelp, isSpecCreating, viewMode, showResetModal, wsState.agentStatus])
+  }, [selectedProject, showAddFeature, showExpandProject, selectedFeature, debugOpen, debugActiveTab, assistantOpen, features, showSettings, showKeyboardHelp, isSpecCreating, viewMode, showResetModal, wsState.agentStatus, hasSpec])
 
   // Combine WebSocket progress with feature data
   const progress = wsState.progress.total > 0 ? wsState.progress : {
@@ -490,7 +490,7 @@ function App() {
       )}
 
       {/* Expand Project Modal - AI-powered bulk feature creation */}
-      {showExpandProject && selectedProject && (
+      {showExpandProject && selectedProject && hasSpec && (
         <ExpandProjectModal
           isOpen={showExpandProject}
           projectName={selectedProject}
diff --git a/ui/src/components/KanbanBoard.tsx b/ui/src/components/KanbanBoard.tsx
index 207ac588..1840c762 100644
--- a/ui/src/components/KanbanBoard.tsx
+++ b/ui/src/components/KanbanBoard.tsx
@@ -51,7 +51,7 @@ export function KanbanBoard({ features, onFeatureClick, onAddFeature, onExpandPr
         onFeatureClick={onFeatureClick}
         onAddFeature={onAddFeature}
         onExpandProject={onExpandProject}
-        showExpandButton={hasFeatures}
+        showExpandButton={hasFeatures && hasSpec}
         onCreateSpec={onCreateSpec}
         showCreateSpec={!hasSpec && !hasFeatures}
       />
diff --git a/ui/src/components/KeyboardShortcutsHelp.tsx b/ui/src/components/KeyboardShortcutsHelp.tsx
index 8ead81fa..aa82a425 100644
--- a/ui/src/components/KeyboardShortcutsHelp.tsx
+++ b/ui/src/components/KeyboardShortcutsHelp.tsx
@@ -19,7 +19,7 @@ const shortcuts: Shortcut[] = [
   { key: 'D', description: 'Toggle debug panel' },
   { key: 'T', description: 'Toggle terminal tab' },
   { key: 'N', description: 'Add new feature', context: 'with project' },
-  { key: 'E', description: 'Expand project with AI', context: 'with features' },
+  { key: 'E', description: 'Expand project with AI', context: 'with spec & features' },
   { key: 'A', description: 'Toggle AI assistant', context: 'with project' },
   { key: 'G', description: 'Toggle Kanban/Graph view', context: 'with project' },
   { key: ',', description: 'Open settings' },
diff --git a/ui/src/hooks/useExpandChat.ts b/ui/src/hooks/useExpandChat.ts
index 91508852..be632a54 100644
--- a/ui/src/hooks/useExpandChat.ts
+++ b/ui/src/hooks/useExpandChat.ts
@@ -107,16 +107,20 @@ export function useExpandChat({
       }, 30000)
     }
 
-    ws.onclose = () => {
+    ws.onclose = (event) => {
       setConnectionStatus('disconnected')
       if (pingIntervalRef.current) {
         clearInterval(pingIntervalRef.current)
         pingIntervalRef.current = null
       }
 
+      // Don't retry on application-level errors (4xxx codes won't resolve on retry)
+      const isAppError = event.code >= 4000 && event.code <= 4999
+
       // Attempt reconnection if not intentionally closed
       if (
         !manuallyDisconnectedRef.current &&
+        !isAppError &&
         reconnectAttempts.current < maxReconnectAttempts &&
         !isCompleteRef.current
       ) {
diff --git a/ui/src/hooks/useSpecChat.ts b/ui/src/hooks/useSpecChat.ts
index b2bac628..3bd09bb2 100644
--- a/ui/src/hooks/useSpecChat.ts
+++ b/ui/src/hooks/useSpecChat.ts
@@ -157,15 +157,18 @@ export function useSpecChat({
       }, 30000)
     }
 
-    ws.onclose = () => {
+    ws.onclose = (event) => {
       setConnectionStatus('disconnected')
       if (pingIntervalRef.current) {
         clearInterval(pingIntervalRef.current)
         pingIntervalRef.current = null
       }
 
+      // Don't retry on application-level errors (4xxx codes won't resolve on retry)
+      const isAppError = event.code >= 4000 && event.code <= 4999
+
       // Attempt reconnection if not intentionally closed
-      if (reconnectAttempts.current < maxReconnectAttempts && !isCompleteRef.current) {
+      if (!isAppError && reconnectAttempts.current < maxReconnectAttempts && !isCompleteRef.current) {
         reconnectAttempts.current++
         const delay = Math.min(1000 * Math.pow(2, reconnectAttempts.current), 10000)
         reconnectTimeoutRef.current = window.setTimeout(connect, delay)
diff --git a/ui/src/hooks/useWebSocket.ts b/ui/src/hooks/useWebSocket.ts
index 1a444359..b9c0a3fe 100644
--- a/ui/src/hooks/useWebSocket.ts
+++ b/ui/src/hooks/useWebSocket.ts
@@ -335,10 +335,14 @@ export function useProjectWebSocket(projectName: string | null) {
         }
       }
 
-      ws.onclose = () => {
+      ws.onclose = (event) => {
         setState(prev => ({ ...prev, isConnected: false }))
         wsRef.current = null
 
+        // Don't retry on application-level errors (4xxx codes won't resolve on retry)
+        const isAppError = event.code >= 4000 && event.code <= 4999
+        if (isAppError) return
+
         // Exponential backoff reconnection
         const delay = Math.min(1000 * Math.pow(2, reconnectAttempts.current), 30000)
         reconnectAttempts.current++