fix(openrouter): clean up registry loading

tests/test_openrouter_registry.py

@@ -23,10 +23,14 @@ class TestOpenRouterModelRegistry:
         assert len(registry.list_models()) > 0
         assert len(registry.list_aliases()) > 0
 
-    def test_registry_initialization_with_live_catalogue_defaults(self):
+    def test_default_init_resolves_live_only_model(self):
         registry = OpenRouterModelRegistry()
 
-        assert registry.list_models()
+        config = registry.resolve("x-ai/grok-4")
+        assert config is not None
+        assert config.model_name == "x-ai/grok-4"
+        assert config.context_window == 256000
+        assert config.supports_extended_thinking is True
 
     def test_custom_config_path(self):
         """Test registry with custom config path."""
@@ -48,17 +52,15 @@ class TestOpenRouterModelRegistry:
 
         try:
             registry = OpenRouterModelRegistry(config_path=temp_path)
-            assert len(registry.list_models()) == 1
             assert "test/model-1" in registry.list_models()
             assert "test1" in registry.list_aliases()
             assert "t1" in registry.list_aliases()
+            assert registry.resolve("x-ai/grok-4") is not None
         finally:
             os.unlink(temp_path)
 
-    def test_environment_variable_override(self):
+    def test_environment_variable_override(self, monkeypatch):
         """Test OPENROUTER_MODELS_CONFIG_PATH environment variable."""
-        original_env = os.environ.get("OPENROUTER_MODELS_CONFIG_PATH")
-
         # Create custom config
         config_data = {
             "models": [
@@ -72,7 +74,7 @@ class TestOpenRouterModelRegistry:
 
         try:
             # Set environment variable
-            os.environ["OPENROUTER_MODELS_CONFIG_PATH"] = temp_path
+            monkeypatch.setenv("OPENROUTER_MODELS_CONFIG_PATH", temp_path)
 
             # Create registry without explicit path
             registry = OpenRouterModelRegistry()
@@ -82,11 +84,6 @@ class TestOpenRouterModelRegistry:
             assert "envtest" in registry.list_aliases()
 
         finally:
-            # Restore environment
-            if original_env is not None:
-                os.environ["OPENROUTER_MODELS_CONFIG_PATH"] = original_env
-            else:
-                del os.environ["OPENROUTER_MODELS_CONFIG_PATH"]
             os.unlink(temp_path)
 
     def test_alias_resolution(self):
@@ -202,9 +199,8 @@ class TestOpenRouterModelRegistry:
         with patch.dict("os.environ", {}, clear=True):
             registry = OpenRouterModelRegistry(config_path="/non/existent/path.json")
 
-        # Should initialize with empty maps
-        assert len(registry.list_models()) == 0
-        assert len(registry.list_aliases()) == 0
+        assert len(registry.list_models()) > 0
+        assert registry.resolve("x-ai/grok-4") is not None
         assert registry.resolve("anything") is None
 
     def test_invalid_json_config(self):
@@ -215,9 +211,8 @@ class TestOpenRouterModelRegistry:
 
         try:
             registry = OpenRouterModelRegistry(config_path=temp_path)
-            # Should handle gracefully and initialize empty
-            assert len(registry.list_models()) == 0
-            assert len(registry.list_aliases()) == 0
+            assert len(registry.list_models()) > 0
+            assert registry.resolve("x-ai/grok-4") is not None
         finally:
             os.unlink(temp_path)
 
@@ -348,6 +343,34 @@ class TestOpenRouterModelRegistry:
         assert "openai/o3" in registry.list_models()
         assert registry.resolve("o3") is not None
 
+    def test_invalid_live_json_keeps_curated_models_working(self):
+        curated_data = {
+            "models": [
+                {
+                    "model_name": "openai/gpt-5.2",
+                    "aliases": ["gpt5.2"],
+                    "context_window": 400000,
+                    "max_output_tokens": 128000,
+                }
+            ]
+        }
+
+        with tempfile.NamedTemporaryFile(mode="w", suffix=".json", delete=False) as curated_file:
+            json.dump(curated_data, curated_file)
+            curated_path = curated_file.name
+
+        with tempfile.NamedTemporaryFile(mode="w", suffix=".json", delete=False) as live_file:
+            live_file.write("{ invalid json }")
+            live_path = live_file.name
+
+        try:
+            registry = OpenRouterModelRegistry(config_path=curated_path, live_config_path=live_path)
+            assert "openai/gpt-5.2" in registry.list_models()
+            assert registry.resolve("gpt5.2") is not None
+        finally:
+            os.unlink(curated_path)
+            os.unlink(live_path)
+
     def test_model_with_all_capabilities(self):
         """Test model with all capability flags."""
         from providers.shared import TemperatureConstraint