diff --git a/main/src/database/database.ts b/main/src/database/database.ts
index 1596d34a..c1ee5f62 100644
--- a/main/src/database/database.ts
+++ b/main/src/database/database.ts
@@ -63,6 +63,51 @@ interface ExecutionDiffRow {
   timestamp: string;
 }
 
+const DEBUG_DB_PANEL_STATE = process.env.PANE_DEBUG_DB_PANEL_STATE === "1";
+const LARGE_PANEL_STATE_FIELDS = new Set([
+  "scrollbackBuffer",
+  "alternateScreenBuffer",
+  "serializedBuffer",
+  "commandHistory",
+  "lastActiveCommand",
+  "outputBuffer",
+]);
+
+function summarizePanelStateField(value: unknown): string {
+  if (typeof value === "string") {
+    return `[string length=${value.length}]`;
+  }
+
+  if (Array.isArray(value)) {
+    return `[array length=${value.length}]`;
+  }
+
+  if (value && typeof value === "object") {
+    return `[object keys=${Object.keys(value).length}]`;
+  }
+
+  return `[${typeof value}]`;
+}
+
+function sanitizePanelStateForLog(value: unknown): unknown {
+  if (Array.isArray(value)) {
+    return value.map(item => sanitizePanelStateForLog(item));
+  }
+
+  if (!value || typeof value !== "object") {
+    return value;
+  }
+
+  return Object.fromEntries(
+    Object.entries(value as Record<string, unknown>).map(([key, nestedValue]) => [
+      key,
+      LARGE_PANEL_STATE_FIELDS.has(key)
+        ? summarizePanelStateField(nestedValue)
+        : sanitizePanelStateForLog(nestedValue),
+    ]),
+  );
+}
+
 export class DatabaseService {
   private db: Database.Database;
 
@@ -3969,6 +4014,15 @@ export class DatabaseService {
           }
         }
 
+        if (DEBUG_DB_PANEL_STATE) {
+          console.log("[DB-DEBUG] updatePanel state merge:", {
+            panelId,
+            updates: sanitizePanelStateForLog(updates.state),
+            existing: sanitizePanelStateForLog(existingState),
+            merged: sanitizePanelStateForLog(mergedState),
+          });
+        }
+
         setClauses.push("state = ?");
         values.push(JSON.stringify(mergedState));
       }
diff --git a/main/src/events.ts b/main/src/events.ts
index 39369d43..4581e3b9 100644
--- a/main/src/events.ts
+++ b/main/src/events.ts
@@ -15,6 +15,13 @@ import type { Project } from './database/models';
 import type { GitStatus } from './types/session';
 import { resourceMonitorService } from './services/resourceMonitorService';
 
+function isArchivedSessionOutputValidation(validation: { error?: string; sessionId?: string }): boolean {
+  return Boolean(
+    validation.sessionId &&
+    validation.error === `Session ${validation.sessionId} is archived`
+  );
+}
+
 export function setupEventListeners(services: AppServices, getMainWindow: () => BrowserWindow | null): void {
   const {
     sessionManager,
@@ -137,6 +144,11 @@ export function setupEventListeners(services: AppServices, getMainWindow: () =>
     // Validate the output has valid session context
     const validation = validateEventContext(output);
     if (!validation.valid) {
+      if (isArchivedSessionOutputValidation(validation)) {
+        console.log(`[Validation] Dropping late session-output for archived session ${validation.sessionId}`);
+        return;
+      }
+
       logValidationFailure('session-output event', validation);
       return; // Don't broadcast invalid events
     }
diff --git a/main/src/services/configManager.ts b/main/src/services/configManager.ts
index 8715ff68..705f9522 100644
--- a/main/src/services/configManager.ts
+++ b/main/src/services/configManager.ts
@@ -153,8 +153,8 @@ export class ConfigManager extends EventEmitter {
   }
 
   private async saveConfig(): Promise<void> {
-    const configJson = JSON.stringify(this.config, null, 2);
     const writeConfig = async () => {
+      const configJson = JSON.stringify(this.config, null, 2);
       await fs.mkdir(this.configDir, { recursive: true });
       const tmpPath = `${this.configPath}.${process.pid}.${Date.now()}.${Math.random().toString(36).slice(2)}.tmp`;
 
diff --git a/main/src/utils/logger.ts b/main/src/utils/logger.ts
index 38ff73bd..38ca6059 100644
--- a/main/src/utils/logger.ts
+++ b/main/src/utils/logger.ts
@@ -13,7 +13,8 @@ const ORIGINAL_CONSOLE = {
   info: console.info
 };
 
-const MAX_LOG_EVENT_CHARS = 16 * 1024;
+const MAX_CONSOLE_LOG_EVENT_CHARS = 16 * 1024;
+const MAX_FILE_LOG_EVENT_BYTES = 64 * 1024;
 
 function sanitizeLogControls(message: string): string {
   let sanitized = '';
@@ -32,6 +33,26 @@ function sanitizeLogControls(message: string): string {
   return sanitized;
 }
 
+function truncateToByteLength(value: string, maxBytes: number): string {
+  if (Buffer.byteLength(value) <= maxBytes) {
+    return value;
+  }
+
+  let low = 0;
+  let high = value.length;
+
+  while (low < high) {
+    const mid = Math.ceil((low + high) / 2);
+    if (Buffer.byteLength(value.slice(0, mid)) <= maxBytes) {
+      low = mid;
+    } else {
+      high = mid - 1;
+    }
+  }
+
+  return value.slice(0, low);
+}
+
 export class Logger {
   private logDir: string;
   private currentLogFile: string;
@@ -147,7 +168,7 @@ export class Logger {
   }
 
   private writeToFile(logMessage: string) {
-    const messageWithNewline = logMessage + '\n';
+    const messageWithNewline = `${this.truncateForFile(logMessage)}\n`;
     
     // Add to queue
     this.writeQueue.push({
@@ -231,26 +252,43 @@ export class Logger {
     }
   }
 
-  private normalizeLogEvent(message: string): string {
+  private normalizeLogEventForConsole(message: string): string {
     const sanitized = sanitizeLogControls(message);
 
-    if (sanitized.length <= MAX_LOG_EVENT_CHARS) {
+    if (sanitized.length <= MAX_CONSOLE_LOG_EVENT_CHARS) {
       return sanitized;
     }
 
-    const omittedChars = sanitized.length - MAX_LOG_EVENT_CHARS;
-    return `${sanitized.slice(0, MAX_LOG_EVENT_CHARS)} ... [truncated ${omittedChars} chars, original=${sanitized.length}]`;
+    const omittedChars = sanitized.length - MAX_CONSOLE_LOG_EVENT_CHARS;
+    return `${sanitized.slice(0, MAX_CONSOLE_LOG_EVENT_CHARS)} ... [truncated ${omittedChars} chars, original=${sanitized.length}]`;
+  }
+
+  private truncateForFile(message: string): string {
+    const sanitized = sanitizeLogControls(message);
+    const originalBytes = Buffer.byteLength(sanitized);
+
+    if (originalBytes <= MAX_FILE_LOG_EVENT_BYTES) {
+      return sanitized;
+    }
+
+    const suffix = ` ... [truncated file log event from ${originalBytes} bytes to ${MAX_FILE_LOG_EVENT_BYTES} bytes]`;
+    const suffixBytes = Buffer.byteLength(suffix);
+    const targetBytes = Math.max(0, MAX_FILE_LOG_EVENT_BYTES - suffixBytes);
+    const truncated = truncateToByteLength(sanitized, targetBytes);
+
+    return `${truncated}${suffix}`;
   }
 
   private log(level: string, message: string, error?: Error) {
     const timestamp = formatForDatabase();
     const errorInfo = error ? ` Error: ${error.message}\nStack: ${error.stack}` : '';
-    const fullMessage = this.normalizeLogEvent(`[${timestamp}] ${level}: ${message}${errorInfo}`);
+    const fullMessage = `[${timestamp}] ${level}: ${message}${errorInfo}`;
+    const consoleMessage = this.normalizeLogEventForConsole(fullMessage);
     
     // Try to log to console, but handle EPIPE errors gracefully
     try {
       // Always log to console using the original console method to avoid recursion
-      this.originalConsole.log(fullMessage);
+      this.originalConsole.log(consoleMessage);
     } catch (consoleError: unknown) {
       // If console logging fails (e.g., EPIPE), just write to file
       if ((consoleError as NodeJS.ErrnoException)?.code !== 'EPIPE' && !this.isInErrorHandler) {
@@ -259,9 +297,9 @@ export class Logger {
         try {
           // For non-EPIPE errors, try to at least write the error to file
           // Use a direct write to avoid potential recursion through writeToFile
-          const errorMessage = `[${timestamp}] ERROR: Failed to write to console: ${(consoleError as Error)?.message || 'Unknown error'}\n`;
+          const errorMessage = `[${timestamp}] ERROR: Failed to write to console: ${(consoleError as Error)?.message || 'Unknown error'}`;
           if (this.logStream && !this.logStream.destroyed) {
-            this.logStream.write(errorMessage);
+            this.logStream.write(`${this.truncateForFile(errorMessage)}\n`);
           }
         } catch {
           // Silently fail - we've done our best