v2.2.0: Fix floating window sizing and state synchronization

- Fix overlay size calculation to use physical pixels instead of scaled logical pixels
- Add proper state synchronization between main app and overlay for close events
- Improve overlay close button functionality with bidirectional communication
- Add comprehensive debug output for screen size analysis
- Update overlay visual tweaks (close button sizing, speed display improvements)

🤖 Generated with [Claude Code](https://claude.ai/code)

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

lib/main.dart

@@ -1,4 +1,5 @@
 import 'package:flutter/material.dart';
+import 'package:flutter/foundation.dart'; // For kDebugMode
 import 'dart:async';
 import 'package:geolocator/geolocator.dart';
 import 'package:wakelock_plus/wakelock_plus.dart';
@@ -8,6 +9,13 @@ import 'gps_service.dart';
 import 'color_themes.dart';
 import 'dart:math' as math; // Import for math.pi
 
+// Debug helper - only prints in debug builds
+void customDebugPrint(String message) {
+  if (kDebugMode) {
+    print(message);
+  }
+}
+
 void main() {
   runApp(const SpeedoApp());
 }
@@ -15,7 +23,7 @@ void main() {
 // Entry point for overlay window
 @pragma("vm:entry-point")
 void overlayMain() {
-  print('[Overlay] 🚀 overlayMain() called');
+  customDebugPrint('[Overlay] 🚀 overlayMain() called');
   runApp(const MaterialApp(
     debugShowCheckedModeBanner: false,
     home: OverlaySpeedometer(),
@@ -61,12 +69,45 @@ class _SpeedometerScreenState extends State<SpeedometerScreen> with WidgetsBindi
   bool _isInBackground = false;
   bool _isOverlayActive = false;
   
+  // Single source of truth for overlay sizing
+  Map<String, int> _getOverlaySize() {
+    final window = WidgetsBinding.instance.platformDispatcher.views.first;
+    final physicalSize = window.physicalSize;
+    final devicePixelRatio = window.devicePixelRatio;
+    final systemSize = physicalSize / devicePixelRatio;
+    
+    customDebugPrint('[Main] 🔍 Screen size analysis:');
+    customDebugPrint('  physicalSize: ${physicalSize.width.round()}x${physicalSize.height.round()}');
+    customDebugPrint('  devicePixelRatio: $devicePixelRatio');
+    customDebugPrint('  calculated systemSize: ${systemSize.width.round()}x${systemSize.height.round()}');
+    
+    // Use actual physical pixels, not scaled logical pixels
+    final overlayWidth = (physicalSize.width * 0.4).round(); // 40% of actual screen width
+    final overlayHeight = (overlayWidth * 0.6).round();
+    
+    customDebugPrint('  using fixed overlay size: ${overlayWidth}x${overlayHeight}');
+    
+    return {'width': overlayWidth, 'height': overlayHeight};
+  }
+
   @override
   void initState() {
     super.initState();
     WidgetsBinding.instance.addObserver(this);
     _initializeGps();
     _enableWakelock();
+    _listenToOverlayMessages();
+  }
+  
+  void _listenToOverlayMessages() {
+    FlutterOverlayWindow.overlayListener.listen((data) {
+      if (data is Map && data['action'] == 'overlayClosed') {
+        customDebugPrint('[Main] 📡 Received overlay close notification');
+        setState(() {
+          _isOverlayActive = false;
+        });
+      }
+    });
   }
 
   Future<void> _enableWakelock() async {
@@ -162,20 +203,11 @@ class _SpeedometerScreenState extends State<SpeedometerScreen> with WidgetsBindi
     final speedText = displaySpeed < 1.0 ? '--' : displaySpeed.toInt().toString();
     final headingText = GpsService.formatHeading(_heading);
     
-    // Get system screen size to share with overlay
-    final window = WidgetsBinding.instance.platformDispatcher.views.first;
-    final systemSize = window.physicalSize / window.devicePixelRatio;
-    
-    print('[Main] 📤 SENDING to overlay:');
-    print('  speedText: "$speedText"');
-    print('  headingText: "$headingText"');
-    print('  direction: ${_heading.toStringAsFixed(1)}°');
-    print('  unit: ${_currentUnit.label}, theme: $_currentThemeIndex');
-    print('  systemScreen: ${systemSize.width.round()}x${systemSize.height.round()}');
-    
-    // Calculate overlay size the same way as when launching
-    final overlayWidth = (systemSize.width * 0.4).round();
-    final overlayHeight = (overlayWidth * 0.5).round();
+    customDebugPrint('[Main] 📤 SENDING to overlay:');
+    customDebugPrint('  speedText: "$speedText"');
+    customDebugPrint('  headingText: "$headingText"');
+    customDebugPrint('  direction: ${_heading.toStringAsFixed(1)}°');
+    customDebugPrint('  unit: ${_currentUnit.label}, theme: $_currentThemeIndex');
     
     FlutterOverlayWindow.shareData({
       'action': 'updateDisplay',
@@ -184,10 +216,6 @@ class _SpeedometerScreenState extends State<SpeedometerScreen> with WidgetsBindi
       'heading': _heading,
       'unitIndex': _currentUnit.index,
       'themeIndex': _currentThemeIndex,
-      'systemScreenWidth': systemSize.width,
-      'systemScreenHeight': systemSize.height,
-      'overlayWidth': overlayWidth.clamp(280, 480).toDouble(),
-      'overlayHeight': overlayHeight.clamp(140, 240).toDouble(),
     });
   }
 
@@ -209,17 +237,10 @@ class _SpeedometerScreenState extends State<SpeedometerScreen> with WidgetsBindi
 
   Future<void> _showFloatingWindow() async {
     try {
-      // Get actual system screen resolution for proportional sizing
-      final window = WidgetsBinding.instance.platformDispatcher.views.first;
-      final systemSize = window.physicalSize / window.devicePixelRatio;
-      final overlayWidth = (systemSize.width * 0.4).round(); // 40% of system screen width
-      final overlayHeight = (overlayWidth * 0.5).round(); // 2:1 aspect ratio
+      // Use centralized sizing function
+      final overlaySize = _getOverlaySize();
       
-      // Debug info for development
-      // print('[Main] System resolution: ${systemSize.width.round()}x${systemSize.height.round()}');
-      // print('[Main] Calculated overlay size: ${overlayWidth}x${overlayHeight}');
-      
-      // Send initial display data to overlay including screen size
+      // Send initial display data WITH size info (only needed on creation)
       final displaySpeed = _currentUnit.convert(_speed);
       final speedText = displaySpeed < 1.0 ? '--' : displaySpeed.toInt().toString();
       final headingText = GpsService.formatHeading(_heading);
@@ -231,10 +252,8 @@ class _SpeedometerScreenState extends State<SpeedometerScreen> with WidgetsBindi
         'heading': _heading,
         'unitIndex': _currentUnit.index,
         'themeIndex': _currentThemeIndex,
-        'systemScreenWidth': systemSize.width,
-        'systemScreenHeight': systemSize.height,
-        'overlayWidth': overlayWidth.clamp(280, 480).toDouble(),
-        'overlayHeight': overlayHeight.clamp(140, 240).toDouble(),
+        'overlayWidth': overlaySize['width']!.toDouble(),
+        'overlayHeight': overlaySize['height']!.toDouble(),
       });
 
       // Show the overlay with proportional sizing based on system resolution
@@ -245,12 +264,12 @@ class _SpeedometerScreenState extends State<SpeedometerScreen> with WidgetsBindi
         flag: OverlayFlag.defaultFlag,
         visibility: NotificationVisibility.visibilityPublic,
         positionGravity: PositionGravity.none,
-        // Use system-based proportional sizing with reasonable limits
-        width: overlayWidth.clamp(280, 480),
-        height: overlayHeight.clamp(140, 240),
+        // Use consistent sizing from centralized function
+        width: overlaySize['width']!,
+        height: overlaySize['height']!,
       );
       
-      print('[Main] 🟢 OVERLAY LAUNCHED - Size: ${overlayWidth.clamp(280, 480)}x${overlayHeight.clamp(140, 240)}');
+      customDebugPrint('[Main] 🟢 OVERLAY LAUNCHED - Size: ${overlaySize['width']}x${overlaySize['height']}');
       setState(() {
         _isOverlayActive = true;
       });
@@ -261,18 +280,18 @@ class _SpeedometerScreenState extends State<SpeedometerScreen> with WidgetsBindi
 
   Future<void> _closeFloatingWindow() async {
     if (!_isOverlayActive) {
-      print('[Main] ⚠️  No overlay to close');
+      customDebugPrint('[Main] ⚠️  No overlay to close');
       return;
     }
     
     try {
       await FlutterOverlayWindow.closeOverlay();
-      print('[Main] 🔴 OVERLAY CLOSED - Requested from main app');
+      customDebugPrint('[Main] 🔴 OVERLAY CLOSED - Requested from main app');
       setState(() {
         _isOverlayActive = false;
       });
     } catch (e) {
-      print('[Main] ❌ Error closing overlay: $e');
+      customDebugPrint('[Main] ❌ Error closing overlay: $e');
     }
   }
   
@@ -415,7 +434,7 @@ class _SpeedometerScreenState extends State<SpeedometerScreen> with WidgetsBindi
           flex: 32,
           child: GestureDetector(
             onTap: () {
-              print('[Main] 🖱️  Navigation area tapped - overlay active: $_isOverlayActive');
+              customDebugPrint('[Main] 🖱️  Navigation area tapped - overlay active: $_isOverlayActive');
               if (_isOverlayActive) {
                 _closeFloatingWindow();
               } else {
@@ -423,7 +442,7 @@ class _SpeedometerScreenState extends State<SpeedometerScreen> with WidgetsBindi
               }
             },
             onLongPress: () {
-              print('[Main] 🖱️  Navigation area long-pressed - overlay active: $_isOverlayActive');
+              customDebugPrint('[Main] 🖱️  Navigation area long-pressed - overlay active: $_isOverlayActive');
               _closeFloatingWindow();
             },
             child: Container(
@@ -541,7 +560,7 @@ class _SpeedometerScreenState extends State<SpeedometerScreen> with WidgetsBindi
           flex: 33,
           child: GestureDetector(
             onTap: () {
-              print('[Main] 🖱️  Navigation area tapped (landscape) - overlay active: $_isOverlayActive');
+              customDebugPrint('[Main] 🖱️  Navigation area tapped (landscape) - overlay active: $_isOverlayActive');
               if (_isOverlayActive) {
                 _closeFloatingWindow();
               } else {
@@ -549,7 +568,7 @@ class _SpeedometerScreenState extends State<SpeedometerScreen> with WidgetsBindi
               }
             },
             onLongPress: () {
-              print('[Main] 🖱️  Navigation area long-pressed (landscape) - overlay active: $_isOverlayActive');
+              customDebugPrint('[Main] 🖱️  Navigation area long-pressed (landscape) - overlay active: $_isOverlayActive');
               _closeFloatingWindow();
             },
             child: Container(
@@ -616,7 +635,7 @@ class _OverlaySpeedometerState extends State<OverlaySpeedometer> {
   @override
   void initState() {
     super.initState();
-    print('[Overlay] 🟢 CREATED - Floating window initialized');
+    customDebugPrint('[Overlay] 🟢 CREATED - Floating window initialized');
     _getSystemScreenSize();
     _listenToMainAppMessages();
   }
@@ -629,18 +648,18 @@ class _OverlaySpeedometerState extends State<OverlaySpeedometer> {
       final devicePixelRatio = window.devicePixelRatio;
       final systemSize = physicalSize / devicePixelRatio;
       
-      print('[Overlay] 🔍 Screen detection:');
-      print('  physicalSize: ${physicalSize.width.round()}x${physicalSize.height.round()}');
-      print('  devicePixelRatio: $devicePixelRatio');
-      print('  calculated systemSize: ${systemSize.width.round()}x${systemSize.height.round()}');
+      customDebugPrint('[Overlay] 🔍 Screen detection:');
+      customDebugPrint('  physicalSize: ${physicalSize.width.round()}x${physicalSize.height.round()}');
+      customDebugPrint('  devicePixelRatio: $devicePixelRatio');
+      customDebugPrint('  calculated systemSize: ${systemSize.width.round()}x${systemSize.height.round()}');
       
       setState(() {
         _systemScreenWidth = systemSize.width;
       });
       
-      print('[Overlay] ✅ _systemScreenWidth set to: ${_systemScreenWidth.round()}');
+      customDebugPrint('[Overlay] ✅ _systemScreenWidth set to: ${_systemScreenWidth.round()}');
     } catch (e) {
-      print('[Overlay] ❌ Error getting system screen size: $e');
+      customDebugPrint('[Overlay] ❌ Error getting system screen size: $e');
       // Fallback to reasonable default
       setState(() {
         _systemScreenWidth = 400;
@@ -668,20 +687,20 @@ class _OverlaySpeedometerState extends State<OverlaySpeedometer> {
           }
         });
         
-        print('[Overlay] 📡 UPDATE received:');
-        print('  speedText: "$_speedText"');
-        print('  headingText: "$_headingText"'); 
-        print('  direction: ${_heading.toStringAsFixed(1)}°');
-        print('  themeIndex: $_currentThemeIndex');
-        print('  systemScreenWidth: ${_systemScreenWidth.round()}');
-        print('  overlaySize from main: ${_overlayWidth.round()}x${_overlayHeight.round()}');
+        customDebugPrint('[Overlay] 📡 UPDATE received:');
+        customDebugPrint('  speedText: "$_speedText"');
+        customDebugPrint('  headingText: "$_headingText"'); 
+        customDebugPrint('  direction: ${_heading.toStringAsFixed(1)}°');
+        customDebugPrint('  themeIndex: $_currentThemeIndex');
+        customDebugPrint('  systemScreenWidth: ${_systemScreenWidth.round()}');
+        customDebugPrint('  overlaySize from main: ${_overlayWidth.round()}x${_overlayHeight.round()}');
       }
     });
   }
 
   @override
   void dispose() {
-    print('[Overlay] 🔴 DESTROYED - Floating window disposed');
+    customDebugPrint('[Overlay] 🔴 DESTROYED - Floating window disposed');
     // No GPS subscription to cancel - overlay is display-only
     super.dispose();
   }
@@ -693,7 +712,7 @@ class _OverlaySpeedometerState extends State<OverlaySpeedometer> {
     // Use overlay dimensions provided by main app (not calculated locally)
     final fontSize = (_overlayWidth * 0.2); // Font size proportional to actual overlay width
     
-    print('[Overlay] 📐 Window size: ${_overlayWidth.round()}x${_overlayHeight.round()}, fontSize: ${fontSize.round()}');
+    customDebugPrint('[Overlay] 📐 Window size: ${_overlayWidth.round()}x${_overlayHeight.round()}, fontSize: ${fontSize.round()}');
 
     return Material(
       color: Colors.transparent,
@@ -724,7 +743,7 @@ class _OverlaySpeedometerState extends State<OverlaySpeedometer> {
                         child: FittedBox(
                           fit: BoxFit.contain,
                           child: Text(
-                            _speedText,
+                            (_speedText == "--" ? "0" : _speedText),
                             style: TextStyle(
                               fontSize: fontSize,
                               fontWeight: FontWeight.w300,
@@ -783,22 +802,29 @@ class _OverlaySpeedometerState extends State<OverlaySpeedometer> {
                 top: 4,
                 right: 4,
                 child: GestureDetector(
-                  onTap: () => FlutterOverlayWindow.closeOverlay(),
+                  onTap: () {
+                    customDebugPrint('[Overlay] 🔴 Close button tapped');
+                    // Notify main app that overlay is closing
+                    FlutterOverlayWindow.shareData({
+                      'action': 'overlayClosed',
+                    });
+                    FlutterOverlayWindow.closeOverlay();
+                  },
                   child: Container(
-                    width: _overlayHeight * 0.2,
-                    height: _overlayHeight * 0.2,
+                    width: 18,
+                    height: 18, // fixed
                     decoration: BoxDecoration(
-                      color: Colors.red.withOpacity(0.6),
+                      color: Colors.transparent,
                       borderRadius: BorderRadius.circular(_overlayHeight * 0.1),
                       border: Border.all(
-                        color: Colors.white.withOpacity(0.8),
+                        color: currentTheme.speedTextSub.withOpacity(0.9),
                         width: 1
                       ),
                     ),
                     child: Icon(
                       Icons.close,
-                      color: Colors.white.withOpacity(0.9),
-                      size: _overlayHeight * 0.15,
+                      color: currentTheme.speedText.withOpacity(0.9),
+                      size: 15,
                     ),
                   ),
                 ),

pubspec.yaml

@@ -2,7 +2,7 @@ name: gps_speedo
 description: "Speedo - A Flutter application."
 publish_to: 'none'
 
-version: 2.1.0+2
+version: 2.2.0+1
 
 environment:
   sdk: ^3.9.0