test(ci): share APKs between jobs and expand smoke tests

CI — build job now uploads both APKs as the 'test-apks' artifact.
smoke-test job downloads them and passes -x assembleDebug
-x assembleDebugAndroidTest to skip recompilation (~4 min saved).
Test results uploaded as 'smoke-test-results' artifact on every run.

Smoke tests expanded from 1 → 11 tests covering:
  - MainActivity launches without crash
  - All 4 bottom-nav tabs are displayed
  - Safety tab: Safety Dashboard, ACTIVATE MOB, ANCHOR WATCH visible
  - Log tab: voice-log mic FAB visible
  - Instruments tab: bottom sheet displayed
  - Map tab: returns from overlay, mapView visible
  - MOB FAB: always visible, visible on Safety tab
  - Record Track FAB: displayed, toggles to Stop Recording, toggles back

MainActivity: moved isRecording observer to initializeUI() so the
FAB content description updates without requiring GPS permission
(needed for emulator tests that run without location permission).

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

3 files changed, 137 insertions, 17 deletions

diff --git a/.github/workflows/android.yml b/.github/workflows/android.yml
index 12b0bc9..150da6f 100644
--- a/.github/workflows/android.yml
+++ b/.github/workflows/android.yml
@@ -27,12 +27,20 @@ jobs:
       run: ./gradlew assembleDebug assembleDebugAndroidTest
       working-directory: android-app
 
-    - name: Upload artifact
+    - name: Upload app APK (Firebase / manual download)
       uses: actions/upload-artifact@v4
       with:
         name: app-debug
         path: android-app/app/build/outputs/apk/debug/app-debug.apk
 
+    - name: Upload test APKs (shared with smoke-test job)
+      uses: actions/upload-artifact@v4
+      with:
+        name: test-apks
+        path: |
+          android-app/app/build/outputs/apk/debug/app-debug.apk
+          android-app/app/build/outputs/apk/androidTest/debug/app-debug-androidTest.apk
+
     - name: upload artifact to Firebase App Distribution
       if: github.ref == 'refs/heads/main'
       uses: wzieba/Firebase-Distribution-Github-Action@v1
@@ -66,7 +74,7 @@ jobs:
 
   smoke-test:
     runs-on: ubuntu-latest
-    # Run after build succeeds so we don't spin up an emulator for a broken build
+    # Run after build succeeds — no point spinning up an emulator for a broken build
     needs: build
 
     steps:
@@ -82,21 +90,36 @@ jobs:
     - name: Grant execute permission for gradlew
       run: chmod +x android-app/gradlew
 
+    # Restore pre-built APKs so the emulator job skips the compile step
+    - name: Download test APKs
+      uses: actions/download-artifact@v4
+      with:
+        name: test-apks
+        path: .   # preserves android-app/app/build/outputs/… directory structure
+
     - name: Enable KVM (faster emulator)
       run: |
         echo 'KERNEL=="kvm", GROUP="kvm", MODE="0666", OPTIONS+="static_node=kvm"' | sudo tee /etc/udev/rules.d/99-kvm4all.rules
         sudo udevadm control --reload-rules
         sudo udevadm trigger --name-match=kvm
 
+    # -x assembleDebug -x assembleDebugAndroidTest: skip recompile, use downloaded APKs
     - name: Run smoke tests on emulator
       uses: reactivecircus/android-emulator-runner@v2
       with:
         api-level: 30
         arch: x86_64
         profile: pixel_3a
-        script: ./gradlew connectedDebugAndroidTest
+        script: ./gradlew connectedDebugAndroidTest -x assembleDebug -x assembleDebugAndroidTest
         working-directory: android-app
 
+    - name: Upload test results
+      if: always()
+      uses: actions/upload-artifact@v4
+      with:
+        name: smoke-test-results
+        path: android-app/app/build/outputs/androidTest-results/
+
     - name: Notify claudomator
       if: always()
       env:
diff --git a/android-app/app/src/androidTest/kotlin/org/terst/nav/MainActivitySmokeTest.kt b/android-app/app/src/androidTest/kotlin/org/terst/nav/MainActivitySmokeTest.kt
index 0824abe..a13ef7f 100644
--- a/android-app/app/src/androidTest/kotlin/org/terst/nav/MainActivitySmokeTest.kt
+++ b/android-app/app/src/androidTest/kotlin/org/terst/nav/MainActivitySmokeTest.kt
@@ -1,18 +1,24 @@
 package org.terst.nav
 
 import androidx.test.core.app.ActivityScenario
+import androidx.test.espresso.Espresso.onView
+import androidx.test.espresso.action.ViewActions.click
+import androidx.test.espresso.assertion.ViewAssertions.matches
+import androidx.test.espresso.matcher.ViewMatchers.isDisplayed
+import androidx.test.espresso.matcher.ViewMatchers.withContentDescription
+import androidx.test.espresso.matcher.ViewMatchers.withId
+import androidx.test.espresso.matcher.ViewMatchers.withText
 import androidx.test.ext.junit.runners.AndroidJUnit4
 import org.junit.Before
 import org.junit.Test
 import org.junit.runner.RunWith
 
 /**
- * Smoke test: verifies MainActivity launches without crashing.
+ * Smoke tests: verify the main UI surfaces launch and respond correctly.
+ * These run on an emulator without GPS permission, so no LocationService.
  *
- * Run on an emulator/device via:
- *   ./gradlew connectedDebugAndroidTest
- *
- * In CI, requires an emulator step before the Gradle task.
+ * Run locally:  ./gradlew connectedDebugAndroidTest
+ * In CI:        smoke-test job via android-emulator-runner
  */
 @RunWith(AndroidJUnit4::class)
 class MainActivitySmokeTest {
@@ -22,14 +28,104 @@ class MainActivitySmokeTest {
         NavApplication.isTesting = true
     }
 
+    // ── Launch ─────────────────────────────────────────────────────────────
+
     @Test
     fun mainActivity_launches_withoutCrash() {
         ActivityScenario.launch(MainActivity::class.java).use { scenario ->
-            // If we reach this line the activity started without throwing.
-            // onActivity lets us assert it is in a resumed state.
             scenario.onActivity { activity ->
                 assert(!activity.isFinishing) { "MainActivity finished immediately after launch" }
             }
         }
     }
+
+    // ── Bottom nav ─────────────────────────────────────────────────────────
+
+    @Test
+    fun bottomNav_allFourTabs_areDisplayed() {
+        ActivityScenario.launch(MainActivity::class.java).use {
+            onView(withText("Map")).check(matches(isDisplayed()))
+            onView(withText("Instruments")).check(matches(isDisplayed()))
+            onView(withText("Log")).check(matches(isDisplayed()))
+            onView(withText("Safety")).check(matches(isDisplayed()))
+        }
+    }
+
+    @Test
+    fun bottomNav_safetyTab_showsSafetyDashboard() {
+        ActivityScenario.launch(MainActivity::class.java).use {
+            onView(withText("Safety")).perform(click())
+            onView(withText("Safety Dashboard")).check(matches(isDisplayed()))
+            onView(withText("ACTIVATE MOB")).check(matches(isDisplayed()))
+            onView(withText("ANCHOR WATCH")).check(matches(isDisplayed()))
+        }
+    }
+
+    @Test
+    fun bottomNav_logTab_showsVoiceLogUi() {
+        ActivityScenario.launch(MainActivity::class.java).use {
+            onView(withText("Log")).perform(click())
+            onView(withContentDescription("Start voice recognition")).check(matches(isDisplayed()))
+        }
+    }
+
+    @Test
+    fun bottomNav_instrumentsTab_isSelectable() {
+        ActivityScenario.launch(MainActivity::class.java).use {
+            onView(withText("Instruments")).perform(click())
+            onView(withId(R.id.instrument_bottom_sheet)).check(matches(isDisplayed()))
+        }
+    }
+
+    @Test
+    fun bottomNav_mapTab_returnsFromOverlay() {
+        ActivityScenario.launch(MainActivity::class.java).use {
+            onView(withText("Safety")).perform(click())
+            onView(withText("Map")).perform(click())
+            onView(withId(R.id.mapView)).check(matches(isDisplayed()))
+        }
+    }
+
+    // ── Persistent FABs ────────────────────────────────────────────────────
+
+    @Test
+    fun fabMob_isAlwaysVisible() {
+        ActivityScenario.launch(MainActivity::class.java).use {
+            onView(withContentDescription("Man Overboard")).check(matches(isDisplayed()))
+        }
+    }
+
+    @Test
+    fun fabMob_remainsVisibleOnSafetyTab() {
+        ActivityScenario.launch(MainActivity::class.java).use {
+            onView(withText("Safety")).perform(click())
+            onView(withContentDescription("Man Overboard")).check(matches(isDisplayed()))
+        }
+    }
+
+    // ── Track recording ────────────────────────────────────────────────────
+
+    @Test
+    fun fabRecordTrack_isDisplayedWithRecordDescription() {
+        ActivityScenario.launch(MainActivity::class.java).use {
+            onView(withContentDescription("Record Track")).check(matches(isDisplayed()))
+        }
+    }
+
+    @Test
+    fun fabRecordTrack_togglesToStopRecording_onFirstClick() {
+        ActivityScenario.launch(MainActivity::class.java).use {
+            onView(withContentDescription("Record Track")).perform(click())
+            onView(withContentDescription("Stop Recording")).check(matches(isDisplayed()))
+        }
+    }
+
+    @Test
+    fun fabRecordTrack_togglesBackToRecord_onSecondClick() {
+        ActivityScenario.launch(MainActivity::class.java).use {
+            onView(withContentDescription("Record Track")).perform(click())
+            onView(withContentDescription("Stop Recording")).perform(click())
+            onView(withContentDescription("Record Track")).check(matches(isDisplayed()))
+        }
+    }
 }
diff --git a/android-app/app/src/main/kotlin/org/terst/nav/MainActivity.kt b/android-app/app/src/main/kotlin/org/terst/nav/MainActivity.kt
index ecaddc0..f887a43 100644
--- a/android-app/app/src/main/kotlin/org/terst/nav/MainActivity.kt
+++ b/android-app/app/src/main/kotlin/org/terst/nav/MainActivity.kt
@@ -88,6 +88,14 @@ class MainActivity : AppCompatActivity(), SafetyFragment.SafetyListener {
         fabRecordTrack.setOnClickListener {
             if (viewModel.isRecording.value) viewModel.stopTrack() else viewModel.startTrack()
         }
+        // Observe immediately — pure UI state, not gated on GPS permission
+        lifecycleScope.launch {
+            viewModel.isRecording.collect { recording ->
+                val icon = if (recording) R.drawable.ic_close else R.drawable.ic_track_record
+                fabRecordTrack.setImageResource(icon)
+                fabRecordTrack.contentDescription = if (recording) "Stop Recording" else "Record Track"
+            }
+        }
     }
 
     private fun setupBottomSheet() {
@@ -262,13 +270,6 @@ class MainActivity : AppCompatActivity(), SafetyFragment.SafetyListener {
                 mapHandler?.updateTrackLayer(style, points)
             }
         }
-        lifecycleScope.launch {
-            viewModel.isRecording.collect { recording ->
-                val icon = if (recording) R.drawable.ic_close else R.drawable.ic_track_record
-                fabRecordTrack.setImageResource(icon)
-                fabRecordTrack.contentDescription = if (recording) "Stop Recording" else "Record Track"
-            }
-        }
     }
 
     private fun startInstrumentSimulation(polarTable: PolarTable) {