feat(#74): verify downstream cortex TLS certs (outbound pinning)

The router is a TLS client to cortexes; the router->cortex hop crosses
the helexa->operator boundary carrying the client's bearer. This pins
that hop to an enrolled cert.

Trust mechanism (the open question): per-cortex enrolled trust anchor.
Each [[cortexes]] entry gets an optional `tls_ca` — a PEM CA (or
self-signed cert) the cortex's TLS cert must chain to. When set, the
router builds a client that trusts ONLY that anchor (platform roots
disabled), so the cortex must present the expected cert and a rogue
endpoint with any other (even publicly-valid) cert is rejected at the
handshake. Enrolment = the operator hands helexa the cortex's cert,
referenced by path in router config. This is the natural model for
self-hosted operators behind their own nginx/private CA, and reuses the
reqwest public API (no custom rustls verifier, no new TLS backend).

- `RouterState` now holds a per-cortex `reqwest::Client` map
  (`client_for`), replacing the single shared client; poller and dispatch
  use the per-cortex client. `build_client(tls_ca)` is the builder.
- Fail closed: a `tls_ca` that can't load omits the cortex from the
  client map — it's never polled or routed to, rather than silently
  degrading to unpinned TLS. The poller treats a missing client (and a
  rejected handshake) as a failed poll, so #72's existing reachability
  debounce excludes it.

Tests (`tls.rs`, 4): a live tokio-rustls HTTPS server proves a client
enrolled with the server's cert is accepted (200) while clients pinned to
a different cert — or using default roots — are rejected; the poller
marks a wrong-cert cortex unreachable while a correctly-enrolled one is
reachable; a missing pin file disables the cortex (fail closed); garbage
PEM is rejected at build. Existing suites updated for the per-cortex
client + new config field.

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01F6o3ddqmYNh9kzdwq6eowh

Cargo.lock

@@ -1933,10 +1933,15 @@ dependencies = [
  "clap",
  "cortex-core",
  "figment",
+ "helexa-stream",
+ "rcgen",
  "reqwest",
+ "rustls",
  "serde",
  "serde_json",
+ "thiserror 2.0.18",
  "tokio",
+ "tokio-rustls",
  "tower-http",
  "tracing",
  "tracing-subscriber",
@@ -2995,6 +3000,16 @@ dependencies = [
  "syn",
 ]
 
+[[package]]
+name = "pem"
+version = "3.0.6"
+source = "registry+https://github.com/rust-lang/crates.io-index"
+checksum = "1d30c53c26bc5b31a98cd02d20f25a7c8567146caf63ed593a9d87b2775291be"
+dependencies = [
+ "base64 0.22.1",
+ "serde_core",
+]
+
 [[package]]
 name = "percent-encoding"
 version = "2.3.2"
@@ -3361,6 +3376,19 @@ dependencies = [
  "crossbeam-utils",
 ]
 
+[[package]]
+name = "rcgen"
+version = "0.13.2"
+source = "registry+https://github.com/rust-lang/crates.io-index"
+checksum = "75e669e5202259b5314d1ea5397316ad400819437857b90861765f24c4cf80a2"
+dependencies = [
+ "pem",
+ "ring",
+ "rustls-pki-types",
+ "time",
+ "yasna",
+]
+
 [[package]]
 name = "reborrow"
 version = "0.5.5"
@@ -5248,6 +5276,15 @@ version = "1.0.1"
 source = "registry+https://github.com/rust-lang/crates.io-index"
 checksum = "cfe53a6657fd280eaa890a3bc59152892ffa3e30101319d168b781ed6529b049"
 
+[[package]]
+name = "yasna"
+version = "0.5.2"
+source = "registry+https://github.com/rust-lang/crates.io-index"
+checksum = "e17bb3549cc1321ae1296b9cdc2698e2b6cb1992adfa19a8c72e5b7a738f44cd"
+dependencies = [
+ "time",
+]
+
 [[package]]
 name = "yoke"
 version = "0.7.5"

crates/helexa-router/Cargo.toml

@@ -15,6 +15,7 @@ path = "src/lib.rs"
 
 [dependencies]
 cortex-core = { workspace = true }
+helexa-stream = { path = "../helexa-stream" }
 
 tokio = { workspace = true }
 axum = { workspace = true }
@@ -24,6 +25,7 @@ serde = { workspace = true }
 serde_json = { workspace = true }
 figment = { workspace = true }
 anyhow = { workspace = true }
+thiserror = { workspace = true }
 clap = { workspace = true }
 tracing = { workspace = true }
 tracing-subscriber = { workspace = true }
@@ -32,3 +34,8 @@ chrono = { workspace = true }
 [dev-dependencies]
 # Jail (isolated cwd + env) for config tests.
 figment = { workspace = true, features = ["test"] }
+# Self-signed cert generation + a minimal HTTPS server for the outbound
+# TLS-pinning tests (#74).
+rcgen = "0.13"
+rustls = "0.23"
+tokio-rustls = "0.26"

crates/helexa-router/src/catalogue.rs

@@ -0,0 +1,243 @@
+//! Federation catalogue (#75) — the router's aggregate `/v1/models`.
+//!
+//! Presents the **deduped union** of every reachable cortex's `/v1/models`
+//! as the router's own catalogue, so an opencode client doing discovery
+//! against the router resolves the whole federation without knowing about
+//! operators or cortexes (resolves #61's "Router/discovery contract").
+//!
+//! Re-tiering: the fractal design is neuron ← cortex ← router. At the
+//! router tier the "nodes" are **cortexes**, so the merged entry's
+//! `feasible_on` / `locations` are rewritten to **operator names**, not the
+//! neuron names a cortex reports. That keeps the federation view honest
+//! ("served by these operators") without leaking each operator's internal
+//! topology (neuron names, per-device VRAM) to end users.
+//!
+//! Conflict resolution when operators advertise the same model with
+//! different enrichment:
+//! - **`limit`** → the *tightest* (smallest `context`), so a client never
+//!   overflows the most-constrained operator that might serve it (same rule
+//!   cortex uses across its neurons).
+//! - **`cost`** → the *cheapest* (lowest input, then output), the
+//!   federation "from" price. Richer policy (a range, region/price-aware
+//!   selection) couples to #68 and is left as a follow-up.
+
+use crate::state::{CortexTopology, entry_feasible};
+use cortex_core::harness::{ModelCost, ModelLimit};
+use cortex_core::node::{CortexModelEntry, ModelLocation, ModelStatus};
+use std::collections::HashMap;
+
+/// Build the federation catalogue: the deduped union of every reachable
+/// cortex's serveable models, merged across operators and sorted by id.
+pub fn aggregate_models(topology: &HashMap<String, CortexTopology>) -> Vec<CortexModelEntry> {
+    // Iterate cortexes in name order so `feasible_on` / `locations` and the
+    // limit/cost tie-breaks are deterministic regardless of map ordering.
+    let mut cortexes: Vec<(&String, &CortexTopology)> = topology.iter().collect();
+    cortexes.sort_by(|a, b| a.0.cmp(b.0));
+
+    let mut merged: HashMap<String, CortexModelEntry> = HashMap::new();
+    for (cortex_name, t) in cortexes {
+        if !t.reachable {
+            continue;
+        }
+        for entry in t.models.values() {
+            // Only surface models the cortex can actually serve — a
+            // catalogue-only entry no neuron can host shouldn't appear in
+            // the federation view.
+            if !entry_feasible(entry) {
+                continue;
+            }
+            merged
+                .entry(entry.id.clone())
+                .and_modify(|acc| merge_into(acc, cortex_name, entry))
+                .or_insert_with(|| router_entry(cortex_name, entry));
+        }
+    }
+
+    let mut out: Vec<CortexModelEntry> = merged.into_values().collect();
+    out.sort_by(|a, b| a.id.cmp(&b.id));
+    out
+}
+
+/// Seed a federation entry from the first cortex that serves the model,
+/// re-tiering `feasible_on` / `locations` to the operator name.
+fn router_entry(cortex: &str, e: &CortexModelEntry) -> CortexModelEntry {
+    CortexModelEntry {
+        id: e.id.clone(),
+        object: "model".into(),
+        created: e.created,
+        owned_by: e.owned_by.clone(),
+        loaded: e.loaded,
+        feasible_on: vec![cortex.to_string()],
+        locations: loaded_location(cortex, e),
+        capabilities: e.capabilities.clone(),
+        limit: e.limit.clone(),
+        cost: e.cost.clone(),
+        tool_call: e.tool_call,
+        reasoning: e.reasoning,
+    }
+}
+
+/// Fold another cortex's view of the same model into the merged entry.
+fn merge_into(acc: &mut CortexModelEntry, cortex: &str, e: &CortexModelEntry) {
+    acc.loaded |= e.loaded;
+    acc.feasible_on.push(cortex.to_string());
+    acc.locations.extend(loaded_location(cortex, e));
+    for cap in &e.capabilities {
+        if !acc.capabilities.contains(cap) {
+            acc.capabilities.push(cap.clone());
+        }
+    }
+    acc.tool_call |= e.tool_call;
+    acc.reasoning |= e.reasoning;
+    acc.limit = tightest_limit(acc.limit.take(), e.limit.clone());
+    acc.cost = cheapest_cost(acc.cost.take(), e.cost.clone());
+}
+
+/// A single cortex-tier location when the model is loaded at that operator;
+/// empty when only cold-loadable. Neuron-level VRAM is deliberately dropped.
+fn loaded_location(cortex: &str, e: &CortexModelEntry) -> Vec<ModelLocation> {
+    if e.loaded {
+        vec![ModelLocation {
+            node: cortex.to_string(),
+            status: ModelStatus::Loaded,
+            vram_estimate_mb: None,
+        }]
+    } else {
+        Vec::new()
+    }
+}
+
+/// Smaller `context` wins — never advertise more headroom than the
+/// most-constrained operator can honour.
+fn tightest_limit(a: Option<ModelLimit>, b: Option<ModelLimit>) -> Option<ModelLimit> {
+    match (a, b) {
+        (None, x) | (x, None) => x,
+        (Some(a), Some(b)) => Some(if b.context < a.context { b } else { a }),
+    }
+}
+
+/// Cheapest by (input, output) price — the federation "from" price.
+fn cheapest_cost(a: Option<ModelCost>, b: Option<ModelCost>) -> Option<ModelCost> {
+    match (a, b) {
+        (None, x) | (x, None) => x,
+        (Some(a), Some(b)) => Some(if (b.input, b.output) < (a.input, a.output) {
+            b
+        } else {
+            a
+        }),
+    }
+}
+
+#[cfg(test)]
+mod tests {
+    use super::*;
+    use crate::state::CortexTopology;
+
+    fn entry(id: &str, loaded: bool, feasible: bool) -> CortexModelEntry {
+        CortexModelEntry {
+            id: id.into(),
+            object: "model".into(),
+            created: 0,
+            owned_by: "helexa".into(),
+            loaded,
+            feasible_on: if feasible || loaded {
+                vec!["some-neuron".into()]
+            } else {
+                vec![]
+            },
+            locations: vec![],
+            capabilities: vec![],
+            limit: None,
+            cost: None,
+            tool_call: false,
+            reasoning: false,
+        }
+    }
+
+    fn cortex(reachable: bool, entries: Vec<CortexModelEntry>) -> CortexTopology {
+        CortexTopology {
+            reachable,
+            consecutive_failures: 0,
+            last_poll: None,
+            healthy_nodes: 1,
+            total_nodes: 1,
+            models: entries.into_iter().map(|e| (e.id.clone(), e)).collect(),
+        }
+    }
+
+    #[test]
+    fn dedupes_and_merges_availability_across_cortexes() {
+        let mut topo = HashMap::new();
+        // c-a: model loaded. c-b: same model only cold-loadable.
+        topo.insert("c-a".into(), cortex(true, vec![entry("m", true, true)]));
+        topo.insert("c-b".into(), cortex(true, vec![entry("m", false, true)]));
+
+        let out = aggregate_models(&topo);
+        assert_eq!(out.len(), 1, "duplicate model id collapses to one");
+        let m = &out[0];
+        assert!(m.loaded, "loaded somewhere → loaded");
+        // feasible_on re-tiered to operator names, both present, sorted.
+        assert_eq!(m.feasible_on, vec!["c-a".to_string(), "c-b".to_string()]);
+        // Only the loaded operator contributes a location, named by operator.
+        assert_eq!(m.locations.len(), 1);
+        assert_eq!(m.locations[0].node, "c-a");
+        assert_eq!(m.locations[0].vram_estimate_mb, None);
+    }
+
+    #[test]
+    fn unreachable_cortex_is_excluded() {
+        let mut topo = HashMap::new();
+        topo.insert("up".into(), cortex(true, vec![entry("m", true, true)]));
+        topo.insert(
+            "down".into(),
+            cortex(false, vec![entry("other", true, true)]),
+        );
+        let out = aggregate_models(&topo);
+        assert_eq!(out.len(), 1);
+        assert_eq!(out[0].id, "m");
+    }
+
+    #[test]
+    fn catalogue_only_infeasible_entries_are_hidden() {
+        let mut topo = HashMap::new();
+        topo.insert("c".into(), cortex(true, vec![entry("ghost", false, false)]));
+        assert!(aggregate_models(&topo).is_empty());
+    }
+
+    #[test]
+    fn preserves_tightest_limit_and_cheapest_cost() {
+        let mut a = entry("m", true, true);
+        a.limit = Some(ModelLimit {
+            context: 32_768,
+            input: None,
+            output: 4096,
+        });
+        a.cost = Some(ModelCost {
+            input: 0.50,
+            output: 1.50,
+            cache_read: None,
+            cache_write: None,
+        });
+        let mut b = entry("m", true, true);
+        b.limit = Some(ModelLimit {
+            context: 16_384, // tighter
+            input: None,
+            output: 4096,
+        });
+        b.cost = Some(ModelCost {
+            input: 0.20, // cheaper
+            output: 0.80,
+            cache_read: None,
+            cache_write: None,
+        });
+
+        let mut topo = HashMap::new();
+        topo.insert("c-a".into(), cortex(true, vec![a]));
+        topo.insert("c-b".into(), cortex(true, vec![b]));
+
+        let out = aggregate_models(&topo);
+        assert_eq!(out.len(), 1);
+        assert_eq!(out[0].limit.as_ref().unwrap().context, 16_384);
+        assert_eq!(out[0].cost.as_ref().unwrap().input, 0.20);
+    }
+}

crates/helexa-router/src/config.rs

@@ -32,6 +32,11 @@ pub struct RouterSettings {
     /// cortex↔neuron poll cadence one tier down.
     #[serde(default = "default_poll_interval_secs")]
     pub poll_interval_secs: u64,
+    /// This router instance's region (e.g. "eu-west"). When set, dispatch
+    /// (#73) prefers cortexes whose `region` matches, before falling back to
+    /// any feasible cortex. `None` → no geo affinity.
+    #[serde(default)]
+    pub region: Option<String>,
 }
 
 fn default_poll_interval_secs() -> u64 {
@@ -41,12 +46,31 @@ fn default_poll_interval_secs() -> u64 {
 /// One downstream cortex the router may proxy to. The router verifies the
 /// cortex's outbound TLS cert (#74) and routes on capacity (#73); it holds
 /// no entitlement logic of its own and forwards the client bearer verbatim.
-#[derive(Debug, Clone, Serialize, Deserialize)]
+#[derive(Debug, Clone, PartialEq, Eq, Serialize, Deserialize)]
 pub struct CortexEndpoint {
     /// Human-readable label (e.g. "lair-cafe").
     pub name: String,
     /// Base URL of the cortex gateway (e.g. "https://cortex.example.com").
     pub endpoint: String,
+    /// Optional region tag (e.g. "eu-west") for geo affinity in dispatch
+    /// (#73). `None` → no region preference applies to this cortex.
+    #[serde(default)]
+    pub region: Option<String>,
+    /// Path to a PEM trust anchor that **enrols** this cortex (#74): the
+    /// expected CA (or self-signed cert) the cortex's TLS cert must chain
+    /// to. When set on an `https://` endpoint, the router builds a client
+    /// that trusts **only** this anchor (platform roots disabled), so the
+    /// outbound router→cortex hop — which carries the client's bearer —
+    /// reaches a cert the router was told to expect, and a rogue endpoint
+    /// presenting any other (even publicly-valid) cert is rejected at the
+    /// TLS handshake. A rejected handshake surfaces as a connection error,
+    /// which the poller (#72) already treats as unreachable → excluded.
+    ///
+    /// `None` → standard platform-root validation (use for cortexes behind
+    /// a publicly-trusted cert, or plaintext `http://` on a private network
+    /// where the WireGuard mesh is the trust boundary).
+    #[serde(default)]
+    pub tls_ca: Option<String>,
 }
 
 impl RouterConfig {
@@ -68,6 +92,7 @@ impl Default for RouterConfig {
             router: RouterSettings {
                 listen: "0.0.0.0:8088".into(),
                 poll_interval_secs: default_poll_interval_secs(),
+                region: None,
             },
             cortexes: vec![],
         }

crates/helexa-router/src/dispatch.rs

@@ -0,0 +1,221 @@
+//! Capacity-aware dispatch (#73) — the router's data path.
+//!
+//! Given an inbound request's `model`, pick a reachable cortex that can
+//! serve it (preferring warm/loaded, region-affine, higher-headroom),
+//! forward the client's bearer **unchanged** (auth stays at cortex), and
+//! stream the response back verbatim via the shared [`helexa_stream`]
+//! module. Cortex's #63-shaped rejections (`429 rate_limit_exceeded`,
+//! `400 context_length_exceeded`, …) pass through untouched. Transport
+//! failures fail over to the next feasible cortex; a genuine HTTP response —
+//! any status — is returned as-is and never retried away.
+//!
+//! The router holds **no entitlement logic**: it routes on capacity, not
+//! budget.
+
+use crate::config::CortexEndpoint;
+use crate::error::envelope_response;
+use crate::state::RouterState;
+use axum::body::Bytes;
+use axum::http::HeaderMap;
+use axum::response::Response;
+use cortex_core::error_envelope::OpenAiError;
+use helexa_stream::{ChunkObserver, StreamError};
+use std::cmp::Reverse;
+use std::collections::HashMap;
+
+/// Retry-After hint (seconds) on the router's own transient rejections.
+const RETRY_AFTER_SECS: u64 = 5;
+
+/// Outcome of choosing where to send a request.
+#[derive(Debug, PartialEq, Eq)]
+pub enum Selection {
+    /// Feasible reachable cortexes, best-first (failover order).
+    Candidates(Vec<CortexEndpoint>),
+    /// Some cortex knows the model but none are reachable right now → 503.
+    NoReachableCapacity,
+    /// No configured cortex serves the model at all → 404.
+    UnknownModel,
+}
+
+/// Rank the reachable cortexes that can serve `model`, best-first.
+///
+/// Ordering (each a tie-break for the next): loaded/warm before cold-loadable
+/// · region match before not · more healthy nodes before fewer · name for
+/// determinism.
+pub async fn select_cortexes(state: &RouterState, model: &str) -> Selection {
+    let topo = state.topology.read().await;
+    let by_name: HashMap<&str, &CortexEndpoint> = state
+        .cortexes
+        .iter()
+        .map(|c| (c.name.as_str(), c))
+        .collect();
+
+    let mut ranked: Vec<Ranked> = Vec::new();
+    let mut known_anywhere = false;
+
+    for (name, t) in topo.iter() {
+        let Some(entry) = t.models.get(model) else {
+            continue;
+        };
+        if !crate::state::entry_feasible(entry) {
+            continue;
+        }
+        // Known even via an unreachable cortex's last-good poll — lets us
+        // tell "temporarily down" (503) from "nobody serves it" (404).
+        known_anywhere = true;
+        if !t.reachable {
+            continue;
+        }
+        let Some(ep) = by_name.get(name.as_str()) else {
+            continue;
+        };
+        let region_match = match (&state.region, &ep.region) {
+            (Some(r), Some(cr)) => r == cr,
+            _ => false,
+        };
+        ranked.push(Ranked {
+            loaded: entry.loaded,
+            region_match,
+            healthy_nodes: t.healthy_nodes,
+            endpoint: (*ep).clone(),
+        });
+    }
+
+    if ranked.is_empty() {
+        return if known_anywhere {
+            Selection::NoReachableCapacity
+        } else {
+            Selection::UnknownModel
+        };
+    }
+
+    ranked.sort_by(|a, b| {
+        // false < true, so negate the "good" booleans to sort good first.
+        (
+            !a.loaded,
+            !a.region_match,
+            Reverse(a.healthy_nodes),
+            &a.endpoint.name,
+        )
+            .cmp(&(
+                !b.loaded,
+                !b.region_match,
+                Reverse(b.healthy_nodes),
+                &b.endpoint.name,
+            ))
+    });
+
+    Selection::Candidates(ranked.into_iter().map(|r| r.endpoint).collect())
+}
+
+struct Ranked {
+    loaded: bool,
+    region_match: bool,
+    healthy_nodes: u32,
+    endpoint: CortexEndpoint,
+}
+
+/// Proxy an inbound inference request to a capacity-bearing cortex.
+///
+/// `path` is the inference path to forward to (same on the cortex, e.g.
+/// `/v1/chat/completions`). The body is parsed only to extract `model`.
+pub async fn dispatch(
+    state: &RouterState,
+    path: &str,
+    headers: HeaderMap,
+    body: Bytes,
+) -> Response {
+    let Some(model) = extract_model(&body) else {
+        return envelope_response(OpenAiError::new(
+            400,
+            "invalid_request_error",
+            "missing_model_field",
+            "missing 'model' field in request body",
+        ));
+    };
+
+    let candidates = match select_cortexes(state, &model).await {
+        Selection::Candidates(c) => c,
+        Selection::UnknownModel => {
+            return envelope_response(
+                OpenAiError::new(
+                    404,
+                    "invalid_request_error",
+                    "model_not_found",
+                    format!("no operator serves model '{model}'"),
+                )
+                .with_param("model"),
+            );
+        }
+        Selection::NoReachableCapacity => {
+            return envelope_response(OpenAiError::service_unavailable(
+                format!("model '{model}' is temporarily unavailable on all operators"),
+                Some(RETRY_AFTER_SECS),
+            ));
+        }
+    };
+
+    // Try candidates in order, failing over only on transport errors. A
+    // genuine HTTP response (any status — including cortex's #63 429/400)
+    // is returned verbatim and never retried away.
+    for ep in &candidates {
+        // A candidate whose pinned TLS client failed to build (#74) is
+        // disabled — skip it and fail over, same as an unreachable cortex.
+        let Some(client) = state.client_for(&ep.name) else {
+            tracing::warn!(cortex = %ep.name, "no TLS client (disabled); skipping candidate");
+            continue;
+        };
+        let url = format!("{}{}", ep.endpoint, path);
+        tracing::info!(cortex = %ep.name, url = %url, model = %model, "dispatching");
+        match helexa_stream::forward_streaming(
+            client,
+            &url,
+            headers.clone(),
+            body.clone(),
+            NoopObserver,
+        )
+        .await
+        {
+            Ok(resp) => return resp,
+            Err(StreamError::Upstream(e)) => {
+                tracing::warn!(
+                    cortex = %ep.name,
+                    url = %url,
+                    error = %e,
+                    "cortex unreachable; failing over"
+                );
+                continue;
+            }
+            Err(StreamError::ResponseBuild(msg)) => {
+                tracing::error!(cortex = %ep.name, error = %msg, "failed to build proxied response");
+                return envelope_response(OpenAiError::without_code(
+                    500,
+                    "api_error",
+                    "failed to build proxied response",
+                ));
+            }
+        }
+    }
+
+    // Every feasible cortex failed to connect.
+    tracing::warn!(model = %model, tried = candidates.len(), "all feasible operators unreachable");
+    envelope_response(OpenAiError::service_unavailable(
+        format!("all operators able to serve '{model}' are unreachable"),
+        Some(RETRY_AFTER_SECS),
+    ))
+}
+
+/// Pull the `model` field out of a request body without re-serialising it.
+fn extract_model(body: &Bytes) -> Option<String> {
+    let v: serde_json::Value = serde_json::from_slice(body).ok()?;
+    v.get("model")?.as_str().map(str::to_string)
+}
+
+/// The router proxies bytes verbatim and keeps no per-request policy, so it
+/// needs no observation hooks. (Token metrics/metering stay at cortex.)
+struct NoopObserver;
+
+impl ChunkObserver for NoopObserver {
+    fn observe(&mut self, _chunk: &[u8]) {}
+    fn finish(&mut self) {}
+}

crates/helexa-router/src/error.rs

@@ -0,0 +1,27 @@
+//! Router adapter from the shared, axum-agnostic
+//! [`cortex_core::error_envelope::OpenAiError`] (#60/#63) to an axum
+//! [`Response`], setting `Retry-After` when the envelope carries one.
+//!
+//! cortex-core owns the envelope shape; this is the only place the router
+//! crosses from that data into axum. Mirrors cortex-gateway's adapter so
+//! the router's own rejections (no feasible operator, all unreachable) are
+//! the same #63-shaped envelopes clients already understand — distinct from
+//! cortex's rejections, which the router proxies through verbatim.
+
+use axum::http::{HeaderValue, StatusCode, header};
+use axum::response::{IntoResponse, Json, Response};
+use cortex_core::error_envelope::OpenAiError;
+
+/// Render an [`OpenAiError`] as an axum response (status + JSON envelope +
+/// optional `Retry-After`).
+pub fn envelope_response(err: OpenAiError) -> Response {
+    let status = StatusCode::from_u16(err.status).unwrap_or(StatusCode::INTERNAL_SERVER_ERROR);
+    let retry_after = err.retry_after_secs;
+    let mut response = (status, Json(err.body())).into_response();
+    if let Some(secs) = retry_after
+        && let Ok(value) = HeaderValue::from_str(&secs.to_string())
+    {
+        response.headers_mut().insert(header::RETRY_AFTER, value);
+    }
+    response
+}

crates/helexa-router/src/handlers.rs

@@ -1,20 +1,63 @@
 use crate::state::RouterState;
-use axum::{Json, Router, extract::State, routing::get};
-use cortex_core::openai::ModelsResponse;
+use crate::{catalogue, dispatch};
+use axum::body::Bytes;
+use axum::http::HeaderMap;
+use axum::response::Response;
+use axum::{Json, Router, extract::State, routing::get, routing::post};
 use serde_json::{Value, json};
 use std::sync::Arc;
 
-/// Routes served by the router skeleton. The inference paths
-/// (`/v1/chat/completions`, `/v1/messages`, …) arrive with capacity-aware
-/// dispatch (#73); for now the router only answers `/health` and a stub
-/// `/v1/models`.
+/// Routes served by the router. Inference paths are capacity-aware-dispatched
+/// (#73) to a downstream cortex; `/health` and a stub `/v1/models` are local.
 pub fn api_routes() -> Router<Arc<RouterState>> {
     Router::new()
+        .route("/v1/chat/completions", post(chat_completions))
+        .route("/v1/completions", post(completions))
+        .route("/v1/responses", post(responses))
+        .route("/v1/messages", post(messages))
         .route("/v1/models", get(list_models))
         .route("/health", get(health))
         .route("/", get(health))
 }
 
+// ── Inference paths — forwarded verbatim to a chosen cortex ──────────
+//
+// Each handler dispatches to the same path on a capacity-bearing cortex.
+// The body is parsed only to read `model`; the bearer and bytes are
+// forwarded unchanged, and the SSE response streams back verbatim.
+
+async fn chat_completions(
+    State(state): State<Arc<RouterState>>,
+    headers: HeaderMap,
+    body: Bytes,
+) -> Response {
+    dispatch::dispatch(&state, "/v1/chat/completions", headers, body).await
+}
+
+async fn completions(
+    State(state): State<Arc<RouterState>>,
+    headers: HeaderMap,
+    body: Bytes,
+) -> Response {
+    dispatch::dispatch(&state, "/v1/completions", headers, body).await
+}
+
+async fn responses(
+    State(state): State<Arc<RouterState>>,
+    headers: HeaderMap,
+    body: Bytes,
+) -> Response {
+    dispatch::dispatch(&state, "/v1/responses", headers, body).await
+}
+
+async fn messages(
+    State(state): State<Arc<RouterState>>,
+    headers: HeaderMap,
+    body: Bytes,
+) -> Response {
+    dispatch::dispatch(&state, "/v1/messages", headers, body).await
+}
+
 /// `GET /health` — router liveness plus a summary of downstream cortex
 /// reachability from the topology poller (#72). `status` reflects the
 /// router process itself (always `ok` if it answers); downstream health is
@@ -32,12 +75,15 @@ async fn health(State(state): State<Arc<RouterState>>) -> Json<Value> {
     }))
 }
 
-/// `GET /v1/models` — empty catalogue stub. The real cross-operator union
-/// (catalogue × topology feasibility, aggregated from each cortex) is the
-/// federation-catalogue issue (#75).
-async fn list_models() -> Json<ModelsResponse> {
-    Json(ModelsResponse {
-        object: "list".into(),
-        data: vec![],
-    })
+/// `GET /v1/models` — the federation catalogue (#75): the deduped union of
+/// every reachable cortex's `/v1/models`, so a client doing discovery
+/// against the router resolves the whole federation without knowing about
+/// operators or cortexes.
+async fn list_models(State(state): State<Arc<RouterState>>) -> Json<Value> {
+    let topo = state.topology.read().await;
+    let data: Vec<Value> = catalogue::aggregate_models(&topo)
+        .iter()
+        .map(|e| json!(e))
+        .collect();
+    Json(json!({ "object": "list", "data": data }))
 }

crates/helexa-router/src/lib.rs

@@ -11,7 +11,10 @@
 //! on capacity (epic #69). A background [`poller`] keeps a live
 //! per-cortex topology (#72) that the dispatcher (#73) will route on.
 
+pub mod catalogue;
 pub mod config;
+pub mod dispatch;
+pub mod error;
 pub mod handlers;
 pub mod poller;
 pub mod state;

crates/helexa-router/src/poller.rs

@@ -8,7 +8,7 @@
 //! then flipped unhealthy and excluded from routing; it recovers on the
 //! next successful poll.
 
-use crate::state::{RouterModelStatus, RouterState};
+use crate::state::RouterState;
 use chrono::Utc;
 use cortex_core::node::CortexModelEntry;
 use serde::Deserialize;
@@ -62,7 +62,19 @@ pub async fn poll_once(state: &RouterState) {
 /// reachability on its own (a cortex serving `/v1/models` is routable even
 /// if `/health` momentarily isn't).
 async fn poll_cortex(state: &RouterState, name: &str, endpoint: &str) {
-    let models = fetch_models(state, endpoint).await;
+    // A cortex whose pinned TLS client failed to build (#74) is disabled:
+    // there is no client to poll with, so it stays unreachable.
+    let Some(client) = state.client_for(name) else {
+        let mut topo = state.topology.write().await;
+        if let Some(entry) = topo.get_mut(name) {
+            entry.consecutive_failures = entry.consecutive_failures.saturating_add(1);
+            entry.reachable = false;
+        }
+        tracing::warn!(cortex = name, "no TLS client (disabled); skipping poll");
+        return;
+    };
+
+    let models = fetch_models(client, endpoint).await;
 
     let mut topo = state.topology.write().await;
     let Some(entry) = topo.get_mut(name) else {
@@ -71,19 +83,7 @@ async fn poll_cortex(state: &RouterState, name: &str, endpoint: &str) {
 
     match models {
         Ok(models) => {
-            entry.models = models
-                .into_iter()
-                .map(|m| {
-                    let feasible = m.loaded || !m.feasible_on.is_empty();
-                    (
-                        m.id,
-                        RouterModelStatus {
-                            loaded: m.loaded,
-                            feasible,
-                        },
-                    )
-                })
-                .collect();
+            entry.models = models.into_iter().map(|m| (m.id.clone(), m)).collect();
             entry.reachable = true;
             entry.consecutive_failures = 0;
             entry.last_poll = Some(Utc::now());
@@ -106,7 +106,7 @@ async fn poll_cortex(state: &RouterState, name: &str, endpoint: &str) {
     drop(topo);
 
     // Best-effort health (node counts). Never flips reachability.
-    if let Some((healthy, total)) = fetch_health(state, endpoint).await {
+    if let Some((healthy, total)) = fetch_health(client, endpoint).await {
         let mut topo = state.topology.write().await;
         if let Some(entry) = topo.get_mut(name) {
             entry.healthy_nodes = healthy;
@@ -117,12 +117,11 @@ async fn poll_cortex(state: &RouterState, name: &str, endpoint: &str) {
 
 /// GET `/v1/models`, returning the parsed entries or a short failure reason.
 async fn fetch_models(
-    state: &RouterState,
+    client: &reqwest::Client,
     endpoint: &str,
 ) -> Result<Vec<CortexModelEntry>, &'static str> {
     let url = format!("{endpoint}/v1/models");
-    let resp = state
-        .http_client
+    let resp = client
         .get(&url)
         .timeout(POLL_TIMEOUT)
         .send()
@@ -140,15 +139,9 @@ async fn fetch_models(
 
 /// GET `/health`, returning `(healthy, total)` node counts. `None` on any
 /// failure — the caller leaves the previous counts in place.
-async fn fetch_health(state: &RouterState, endpoint: &str) -> Option<(u32, u32)> {
+async fn fetch_health(client: &reqwest::Client, endpoint: &str) -> Option<(u32, u32)> {
     let url = format!("{endpoint}/health");
-    let resp = state
-        .http_client
-        .get(&url)
-        .timeout(POLL_TIMEOUT)
-        .send()
-        .await
-        .ok()?;
+    let resp = client.get(&url).timeout(POLL_TIMEOUT).send().await.ok()?;
     if !resp.status().is_success() {
         return None;
     }

crates/helexa-router/src/state.rs

@@ -1,5 +1,6 @@
 use crate::config::{CortexEndpoint, RouterConfig};
 use chrono::{DateTime, Utc};
+use cortex_core::node::CortexModelEntry;
 use std::collections::HashMap;
 use std::time::Duration;
 use tokio::sync::RwLock;
@@ -14,8 +15,15 @@ use tokio::sync::RwLock;
 pub struct RouterState {
     /// Downstream cortex endpoints, as configured.
     pub cortexes: Vec<CortexEndpoint>,
-    /// Shared client for polling (and, later, proxying to) cortexes.
-    pub http_client: reqwest::Client,
+    /// Per-cortex HTTP client, keyed by cortex name (#74). A cortex enrolled
+    /// with a `tls_ca` gets a client that trusts only that anchor; others
+    /// get a default client. A cortex whose `tls_ca` failed to load is
+    /// **absent** here — `client_for` returns `None` and it is never
+    /// polled or routed to (fail closed: a misconfigured pin must not
+    /// silently fall back to unpinned TLS).
+    clients: HashMap<String, reqwest::Client>,
+    /// This router instance's region, for dispatch geo affinity (#73).
+    pub region: Option<String>,
     /// How often the poller refreshes the topology.
     pub poll_interval: Duration,
     /// Live per-cortex topology, keyed by cortex name. Pre-populated from
@@ -40,19 +48,16 @@ pub struct CortexTopology {
     /// load signal; #73 refines headroom). 0/0 until first health poll.
     pub healthy_nodes: u32,
     pub total_nodes: u32,
-    /// Per-model serveability, keyed by model id, from `/v1/models`.
-    pub models: HashMap<String, RouterModelStatus>,
+    /// The cortex's full `/v1/models` entries, keyed by model id. Stored
+    /// whole (not distilled to a loaded/feasible bool) so the federation
+    /// catalogue (#75) can preserve per-model `limit`/`cost`/capabilities.
+    pub models: HashMap<String, CortexModelEntry>,
 }
 
-/// What a cortex can do with one model, distilled from its `/v1/models`
-/// entry to the two facts the router routes on.
-#[derive(Debug, Clone)]
-pub struct RouterModelStatus {
-    /// The model is loaded on at least one of the cortex's neurons.
-    pub loaded: bool,
-    /// The cortex can serve it — loaded now, or feasible to cold-load
-    /// (catalogue × topology says some neuron can host it).
-    pub feasible: bool,
+/// Whether a cortex can serve this model — loaded now, or feasible to
+/// cold-load (its catalogue × topology says some neuron can host it).
+pub fn entry_feasible(entry: &CortexModelEntry) -> bool {
+    entry.loaded || !entry.feasible_on.is_empty()
 }
 
 impl RouterState {
@@ -63,14 +68,42 @@ impl RouterState {
             .map(|c| (c.name.clone(), CortexTopology::default()))
             .collect();
 
+        // One client per cortex. A `tls_ca` that fails to load omits the
+        // cortex from the map (fail closed) rather than degrading to an
+        // unpinned client.
+        let mut clients = HashMap::new();
+        for c in &config.cortexes {
+            match build_client(c.tls_ca.as_deref()) {
+                Ok(client) => {
+                    clients.insert(c.name.clone(), client);
+                }
+                Err(e) => {
+                    tracing::error!(
+                        cortex = %c.name,
+                        tls_ca = c.tls_ca.as_deref().unwrap_or(""),
+                        error = %e,
+                        "failed to build pinned TLS client; cortex disabled (fail closed)"
+                    );
+                }
+            }
+        }
+
         Self {
             cortexes: config.cortexes.clone(),
-            http_client: reqwest::Client::new(),
+            clients,
+            region: config.router.region.clone(),
             poll_interval: Duration::from_secs(config.router.poll_interval_secs),
             topology: RwLock::new(topology),
         }
     }
 
+    /// The HTTP client to use for `name`, or `None` if the cortex is
+    /// disabled (its `tls_ca` failed to load). Callers must treat `None` as
+    /// "not routable / not pollable".
+    pub fn client_for(&self, name: &str) -> Option<&reqwest::Client> {
+        self.clients.get(name)
+    }
+
     /// Names of reachable cortexes that can serve `model_id` (loaded or
     /// feasible to cold-load). Groundwork for capacity-aware dispatch (#73);
     /// unreachable cortexes are excluded by construction.
@@ -78,8 +111,34 @@ impl RouterState {
         let topo = self.topology.read().await;
         topo.iter()
             .filter(|(_, t)| t.reachable)
-            .filter(|(_, t)| t.models.get(model_id).is_some_and(|m| m.feasible))
+            .filter(|(_, t)| t.models.get(model_id).is_some_and(entry_feasible))
             .map(|(name, _)| name.clone())
             .collect()
     }
 }
+
+/// Build a cortex HTTP client. With `tls_ca` set, the client trusts **only**
+/// that PEM anchor (platform roots disabled) — pinning the router→cortex hop
+/// to an enrolled cert (#74). Without it, standard platform-root validation.
+pub fn build_client(tls_ca: Option<&str>) -> Result<reqwest::Client, BuildClientError> {
+    let mut builder = reqwest::Client::builder();
+    if let Some(path) = tls_ca {
+        let pem = std::fs::read(path).map_err(|e| BuildClientError::Read(path.to_string(), e))?;
+        let cert = reqwest::Certificate::from_pem(&pem).map_err(BuildClientError::Parse)?;
+        builder = builder
+            .tls_built_in_root_certs(false)
+            .add_root_certificate(cert);
+    }
+    builder.build().map_err(BuildClientError::Build)
+}
+
+/// Why a cortex's pinned client could not be built (→ cortex disabled).
+#[derive(Debug, thiserror::Error)]
+pub enum BuildClientError {
+    #[error("reading TLS anchor '{0}'")]
+    Read(String, #[source] std::io::Error),
+    #[error("parsing TLS anchor PEM")]
+    Parse(#[source] reqwest::Error),
+    #[error("building HTTP client")]
+    Build(#[source] reqwest::Error),
+}

crates/helexa-router/tests/catalogue.rs

@@ -0,0 +1,132 @@
+//! End-to-end federation-catalogue test for #75: poll two mock cortexes
+//! that overlap on a model, then `GET /v1/models` on the router and verify
+//! the deduped union with merged availability and preserved limit/cost.
+
+use axum::Router;
+use axum::routing::get;
+use helexa_router::config::{CortexEndpoint, RouterConfig};
+use helexa_router::poller::poll_once;
+use helexa_router::state::RouterState;
+use serde_json::{Value, json};
+use std::sync::Arc;
+use tokio::net::TcpListener;
+
+/// Spawn a mock cortex serving the given `/v1/models` `data` array.
+async fn spawn_cortex(models: Value) -> String {
+    let models = Arc::new(models);
+    let app = Router::new()
+        .route(
+            "/v1/models",
+            get({
+                let models = Arc::clone(&models);
+                move || {
+                    let models = Arc::clone(&models);
+                    async move { axum::Json(json!({ "object": "list", "data": &*models })) }
+                }
+            }),
+        )
+        .route(
+            "/health",
+            get(|| async { axum::Json(json!({"status":"ok","nodes":{"healthy":1,"total":1}})) }),
+        );
+    let listener = TcpListener::bind("127.0.0.1:0").await.unwrap();
+    let addr = listener.local_addr().unwrap();
+    tokio::spawn(async move {
+        axum::serve(listener, app).await.unwrap();
+    });
+    format!("http://{addr}")
+}
+
+/// Spawn the router (with poller) wired to the given cortex endpoints, and
+/// poll once synchronously so the topology is populated before we query.
+async fn spawn_router(cortexes: Vec<CortexEndpoint>) -> String {
+    let cfg = RouterConfig {
+        cortexes,
+        ..Default::default()
+    };
+    let state = Arc::new(RouterState::from_config(&cfg));
+    poll_once(&state).await; // deterministic: fill topology now
+
+    let app = helexa_router::build_app(Arc::clone(&state));
+    let listener = TcpListener::bind("127.0.0.1:0").await.unwrap();
+    let addr = listener.local_addr().unwrap();
+    tokio::spawn(async move {
+        axum::serve(listener, app).await.unwrap();
+    });
+    format!("http://{addr}")
+}
+
+fn model(id: &str, loaded: bool, feasible_on: &[&str], ctx: u64, input_cost: f64) -> Value {
+    json!({
+        "id": id,
+        "object": "model",
+        "created": 0,
+        "owned_by": "helexa",
+        "loaded": loaded,
+        "feasible_on": feasible_on,
+        "locations": [],
+        "limit": { "context": ctx, "output": 4096 },
+        "cost": { "input": input_cost, "output": input_cost * 3.0 }
+    })
+}
+
+#[tokio::test]
+async fn federation_catalogue_dedupes_and_preserves_limit_cost() {
+    // cortex A: "shared" loaded (ctx 32768, $0.50) + "only-a" loaded.
+    let a = spawn_cortex(json!([
+        model("shared", true, &["beast"], 32_768, 0.50),
+        model("only-a", true, &["beast"], 8_192, 1.00),
+    ]))
+    .await;
+    // cortex B: "shared" cold-loadable, tighter ctx (16384), cheaper ($0.20).
+    let b = spawn_cortex(json!([model("shared", false, &["benjy"], 16_384, 0.20)])).await;
+
+    let router = spawn_router(vec![
+        CortexEndpoint {
+            name: "op-a".into(),
+            endpoint: a,
+            region: None,
+            tls_ca: None,
+        },
+        CortexEndpoint {
+            name: "op-b".into(),
+            endpoint: b,
+            region: None,
+            tls_ca: None,
+        },
+    ])
+    .await;
+
+    let body: Value = reqwest::get(format!("{router}/v1/models"))
+        .await
+        .unwrap()
+        .json()
+        .await
+        .unwrap();
+
+    assert_eq!(body["object"], "list");
+    let data = body["data"].as_array().unwrap();
+    // Deduped union: "shared" once + "only-a".
+    assert_eq!(data.len(), 2);
+
+    let shared = data.iter().find(|m| m["id"] == "shared").unwrap();
+    // Loaded somewhere (op-a) → loaded.
+    assert_eq!(shared["loaded"], true);
+    // feasible_on re-tiered to operator names, both present, sorted.
+    let feasible: Vec<&str> = shared["feasible_on"]
+        .as_array()
+        .unwrap()
+        .iter()
+        .map(|v| v.as_str().unwrap())
+        .collect();
+    assert_eq!(feasible, vec!["op-a", "op-b"]);
+    // Tightest limit (16384) and cheapest cost ($0.20) win.
+    assert_eq!(shared["limit"]["context"], 16_384);
+    assert_eq!(shared["cost"]["input"], 0.20);
+    // Loaded location named by operator, no neuron VRAM leaked.
+    let locs = shared["locations"].as_array().unwrap();
+    assert_eq!(locs.len(), 1);
+    assert_eq!(locs[0]["node"], "op-a");
+
+    assert!(data.iter().any(|m| m["id"] == "only-a"));
+}

crates/helexa-router/tests/dispatch.rs

@@ -0,0 +1,301 @@
+//! Capacity-aware dispatch acceptance tests for #73.
+//!
+//! Covers: a request routes to a cortex serving the model; the client's
+//! bearer reaches the cortex; cortex's #63 rejections pass through verbatim
+//! and are NOT retried away; transport failure fails over to another
+//! feasible cortex; unknown model → 404, no reachable capacity → 503; and
+//! the selection ranking (warm/region/headroom).
+
+use axum::body::Bytes;
+use axum::extract::State;
+use axum::http::{HeaderMap, StatusCode};
+use axum::response::{IntoResponse, Response};
+use axum::routing::post;
+use axum::{Json, Router};
+use cortex_core::node::CortexModelEntry;
+use helexa_router::config::{CortexEndpoint, RouterConfig};
+use helexa_router::dispatch::{Selection, dispatch, select_cortexes};
+use helexa_router::state::{CortexTopology, RouterState};
+use serde_json::{Value, json};
+use std::collections::HashMap;
+use tokio::net::TcpListener;
+
+/// A minimal `CortexModelEntry` for MODEL with the given serveability.
+fn model_entry(loaded: bool, feasible: bool) -> CortexModelEntry {
+    CortexModelEntry {
+        id: MODEL.into(),
+        object: "model".into(),
+        created: 0,
+        owned_by: "helexa".into(),
+        loaded,
+        feasible_on: if feasible || loaded {
+            vec!["n".into()]
+        } else {
+            vec![]
+        },
+        locations: vec![],
+        capabilities: vec![],
+        limit: None,
+        cost: None,
+        tool_call: false,
+        reasoning: false,
+    }
+}
+
+const MODEL: &str = "Qwen/Qwen3-Coder-30B";
+
+// ── Mock cortex backend ──────────────────────────────────────────────
+
+/// Behaviour of a mock cortex, carried in axum State.
+#[derive(Clone)]
+struct MockCortex {
+    /// Identifies which cortex answered, echoed in the 200 body.
+    name: &'static str,
+    /// When true, return a genuine #63-shaped `429 rate_limit_exceeded`.
+    rate_limited: bool,
+}
+
+async fn mock_handler(State(m): State<MockCortex>, headers: HeaderMap) -> Response {
+    if m.rate_limited {
+        return (
+            StatusCode::TOO_MANY_REQUESTS,
+            Json(json!({"error":{"type":"rate_limit_error","code":"rate_limit_exceeded","message":"slow down","param":null}})),
+        )
+            .into_response();
+    }
+    let auth = headers
+        .get("authorization")
+        .and_then(|v| v.to_str().ok())
+        .unwrap_or("")
+        .to_string();
+    Json(json!({ "served_by": m.name, "auth_seen": auth })).into_response()
+}
+
+async fn spawn_cortex(mock: MockCortex) -> String {
+    let app = Router::new()
+        .route("/v1/chat/completions", post(mock_handler))
+        .with_state(mock);
+    let listener = TcpListener::bind("127.0.0.1:0").await.unwrap();
+    let addr = listener.local_addr().unwrap();
+    tokio::spawn(async move {
+        axum::serve(listener, app).await.unwrap();
+    });
+    format!("http://{addr}")
+}
+
+fn ok_cortex(name: &'static str) -> MockCortex {
+    MockCortex {
+        name,
+        rate_limited: false,
+    }
+}
+
+// ── Helpers to build state with a hand-set topology ──────────────────
+
+fn state_with(cortexes: Vec<CortexEndpoint>, region: Option<String>) -> RouterState {
+    let cfg = RouterConfig {
+        cortexes,
+        ..Default::default()
+    };
+    let mut state = RouterState::from_config(&cfg);
+    state.region = region;
+    state
+}
+
+/// Overwrite the topology entry for `name` so tests control reachability and
+/// model serveability directly (no live poll).
+async fn set_topology(
+    state: &RouterState,
+    name: &str,
+    reachable: bool,
+    loaded: bool,
+    feasible: bool,
+    healthy_nodes: u32,
+) {
+    let mut topo = state.topology.write().await;
+    let mut models = HashMap::new();
+    models.insert(MODEL.to_string(), model_entry(loaded, feasible));
+    topo.insert(
+        name.to_string(),
+        CortexTopology {
+            reachable,
+            consecutive_failures: 0,
+            last_poll: None,
+            healthy_nodes,
+            total_nodes: healthy_nodes,
+            models,
+        },
+    );
+}
+
+fn ep(name: &str, endpoint: &str, region: Option<&str>) -> CortexEndpoint {
+    CortexEndpoint {
+        name: name.into(),
+        endpoint: endpoint.into(),
+        region: region.map(str::to_string),
+        tls_ca: None,
+    }
+}
+
+fn chat_body() -> Bytes {
+    Bytes::from(format!("{{\"model\":\"{MODEL}\",\"stream\":false}}"))
+}
+
+async fn body_json(resp: Response) -> (StatusCode, Value) {
+    let status = resp.status();
+    let bytes = axum::body::to_bytes(resp.into_body(), usize::MAX)
+        .await
+        .unwrap();
+    let v = serde_json::from_slice(&bytes).unwrap_or(Value::Null);
+    (status, v)
+}
+
+// ── Tests ────────────────────────────────────────────────────────────
+
+#[tokio::test]
+async fn routes_to_serving_cortex_and_forwards_bearer() {
+    let url = spawn_cortex(ok_cortex("c1")).await;
+    let state = state_with(vec![ep("c1", &url, None)], None);
+    set_topology(&state, "c1", true, true, true, 2).await;
+
+    let mut headers = HeaderMap::new();
+    headers.insert("authorization", "Bearer sk-test-123".parse().unwrap());
+
+    let resp = dispatch(&state, "/v1/chat/completions", headers, chat_body()).await;
+    let (status, body) = body_json(resp).await;
+
+    assert_eq!(status, StatusCode::OK);
+    assert_eq!(body["served_by"], "c1");
+    // Bearer reached the cortex unchanged.
+    assert_eq!(body["auth_seen"], "Bearer sk-test-123");
+}
+
+#[tokio::test]
+async fn cortex_429_passes_through_and_is_not_retried() {
+    // c1 (ranked first: loaded) returns a genuine 429; c2 would return 200.
+    let c1 = spawn_cortex(MockCortex {
+        name: "c1",
+        rate_limited: true,
+    })
+    .await;
+    let c2 = spawn_cortex(ok_cortex("c2")).await;
+    let state = state_with(vec![ep("c1", &c1, None), ep("c2", &c2, None)], None);
+    // Both reachable + loaded; c1 has more headroom so it ranks first.
+    set_topology(&state, "c1", true, true, true, 5).await;
+    set_topology(&state, "c2", true, true, true, 1).await;
+
+    let resp = dispatch(
+        &state,
+        "/v1/chat/completions",
+        HeaderMap::new(),
+        chat_body(),
+    )
+    .await;
+    let (status, body) = body_json(resp).await;
+
+    // The genuine 4xx is returned verbatim — NOT retried to c2.
+    assert_eq!(status, StatusCode::TOO_MANY_REQUESTS);
+    assert_eq!(body["error"]["code"], "rate_limit_exceeded");
+    assert!(body.get("served_by").is_none(), "must not have hit c2");
+}
+
+#[tokio::test]
+async fn fails_over_to_next_cortex_on_transport_error() {
+    // c_dead ranks first (more headroom) but its endpoint is a closed port;
+    // c_live is the fallback. The router must fail over and c_live serves.
+    let live = spawn_cortex(ok_cortex("c_live")).await;
+    let state = state_with(
+        vec![
+            ep("c_dead", "http://127.0.0.1:1", None),
+            ep("c_live", &live, None),
+        ],
+        None,
+    );
+    set_topology(&state, "c_dead", true, true, true, 9).await;
+    set_topology(&state, "c_live", true, true, true, 1).await;
+
+    let resp = dispatch(
+        &state,
+        "/v1/chat/completions",
+        HeaderMap::new(),
+        chat_body(),
+    )
+    .await;
+    let (status, body) = body_json(resp).await;
+
+    assert_eq!(status, StatusCode::OK);
+    assert_eq!(body["served_by"], "c_live");
+}
+
+#[tokio::test]
+async fn unknown_model_is_404() {
+    let state = state_with(vec![ep("c1", "http://127.0.0.1:1", None)], None);
+    // Topology has no entry for MODEL at all.
+    let resp = dispatch(
+        &state,
+        "/v1/chat/completions",
+        HeaderMap::new(),
+        chat_body(),
+    )
+    .await;
+    let (status, body) = body_json(resp).await;
+    assert_eq!(status, StatusCode::NOT_FOUND);
+    assert_eq!(body["error"]["code"], "model_not_found");
+}
+
+#[tokio::test]
+async fn known_but_all_unreachable_is_503() {
+    let state = state_with(vec![ep("c1", "http://127.0.0.1:1", None)], None);
+    // Cortex knows the model (from a prior good poll) but is now unreachable.
+    set_topology(&state, "c1", false, true, true, 2).await;
+    let resp = dispatch(
+        &state,
+        "/v1/chat/completions",
+        HeaderMap::new(),
+        chat_body(),
+    )
+    .await;
+    let (status, body) = body_json(resp).await;
+    assert_eq!(status, StatusCode::SERVICE_UNAVAILABLE);
+    assert_eq!(body["error"]["code"], "service_unavailable");
+}
+
+#[tokio::test]
+async fn missing_model_field_is_400() {
+    let state = state_with(vec![ep("c1", "http://127.0.0.1:1", None)], None);
+    let resp = dispatch(
+        &state,
+        "/v1/chat/completions",
+        HeaderMap::new(),
+        Bytes::from_static(b"{\"messages\":[]}"),
+    )
+    .await;
+    let (status, body) = body_json(resp).await;
+    assert_eq!(status, StatusCode::BAD_REQUEST);
+    assert_eq!(body["error"]["code"], "missing_model_field");
+}
+
+#[tokio::test]
+async fn ranking_prefers_loaded_then_region_then_headroom() {
+    // Router is in eu-west. Candidates:
+    //   warm-eu : loaded, region match, 1 node   → best
+    //   warm-us : loaded, no region,    9 nodes
+    //   cold-eu : feasible only, region match     → worst (cold)
+    let state = state_with(
+        vec![
+            ep("warm-eu", "http://127.0.0.1:1", Some("eu-west")),
+            ep("warm-us", "http://127.0.0.1:1", Some("us-east")),
+            ep("cold-eu", "http://127.0.0.1:1", Some("eu-west")),
+        ],
+        Some("eu-west".into()),
+    );
+    set_topology(&state, "warm-eu", true, true, true, 1).await;
+    set_topology(&state, "warm-us", true, true, true, 9).await;
+    set_topology(&state, "cold-eu", true, false, true, 5).await;
+
+    let Selection::Candidates(order) = select_cortexes(&state, MODEL).await else {
+        panic!("expected candidates");
+    };
+    let names: Vec<&str> = order.iter().map(|e| e.name.as_str()).collect();
+    assert_eq!(names, vec!["warm-eu", "warm-us", "cold-eu"]);
+}

crates/helexa-router/tests/skeleton.rs

@@ -31,10 +31,14 @@ async fn health_reports_configured_cortex_count() {
         CortexEndpoint {
             name: "a".into(),
             endpoint: "https://a.example.com".into(),
+            region: None,
+            tls_ca: None,
         },
         CortexEndpoint {
             name: "b".into(),
             endpoint: "https://b.example.com".into(),
+            region: None,
+            tls_ca: None,
         },
     ])
     .await;

crates/helexa-router/tests/tls.rs

@@ -0,0 +1,210 @@
+//! Outbound TLS pinning tests for #74.
+//!
+//! Proves the router, as a TLS client to cortexes, reaches a cortex
+//! presenting its **enrolled** cert and rejects one presenting an
+//! unexpected (or untrusted) cert — and that a rejected handshake flows
+//! through the existing reachability path (#72) to exclude the cortex.
+//!
+//! A minimal `tokio-rustls` HTTPS server presents a self-signed cert; the
+//! router's `reqwest` client (native-tls) validates against the PEM anchor
+//! enrolled in config. Server (rustls) and client (native-tls) interoperate
+//! at the protocol level — what matters is the trust decision.
+
+use helexa_router::config::{CortexEndpoint, RouterConfig};
+use helexa_router::poller::poll_once;
+use helexa_router::state::{RouterState, build_client};
+use std::io::Write;
+use std::sync::Arc;
+use tokio::io::{AsyncReadExt, AsyncWriteExt};
+use tokio::net::TcpListener;
+use tokio_rustls::TlsAcceptor;
+
+/// A self-signed cert: PEM (for the reqwest pin file) + DER cert/key (for
+/// the rustls server).
+struct TestCert {
+    cert_pem: String,
+    cert_der: rustls::pki_types::CertificateDer<'static>,
+    key_der: Vec<u8>,
+}
+
+fn make_cert() -> TestCert {
+    let key = rcgen::generate_simple_self_signed(vec!["127.0.0.1".to_string()]).unwrap();
+    TestCert {
+        cert_pem: key.cert.pem(),
+        cert_der: key.cert.der().clone(),
+        key_der: key.key_pair.serialize_der(),
+    }
+}
+
+/// Write a cert PEM to a unique temp file (named by `tag`) and return the
+/// path. `tag` is caller-unique (we use the bound port), so no randomness.
+fn write_pem(tag: &str, pem: &str) -> String {
+    let path = std::env::temp_dir().join(format!("helexa-router-tls-{tag}.pem"));
+    let mut f = std::fs::File::create(&path).unwrap();
+    f.write_all(pem.as_bytes()).unwrap();
+    path.to_string_lossy().into_owned()
+}
+
+/// Spawn a minimal HTTPS server presenting `cert`, answering every request
+/// with a canned `/v1/models`-shaped 200. Returns its `https://` base URL.
+async fn spawn_https(cert: &TestCert) -> String {
+    let _ = rustls::crypto::aws_lc_rs::default_provider().install_default();
+
+    let key = rustls::pki_types::PrivateKeyDer::Pkcs8(rustls::pki_types::PrivatePkcs8KeyDer::from(
+        cert.key_der.clone(),
+    ));
+    let config = rustls::ServerConfig::builder()
+        .with_no_client_auth()
+        .with_single_cert(vec![cert.cert_der.clone()], key)
+        .unwrap();
+    let acceptor = TlsAcceptor::from(Arc::new(config));
+
+    let listener = TcpListener::bind("127.0.0.1:0").await.unwrap();
+    let addr = listener.local_addr().unwrap();
+    tokio::spawn(async move {
+        loop {
+            let Ok((stream, _)) = listener.accept().await else {
+                continue;
+            };
+            let acceptor = acceptor.clone();
+            tokio::spawn(async move {
+                if let Ok(mut tls) = acceptor.accept(stream).await {
+                    let mut buf = [0u8; 2048];
+                    let _ = tls.read(&mut buf).await; // consume request line/headers
+                    let body = "{\"object\":\"list\",\"data\":[]}";
+                    let resp = format!(
+                        "HTTP/1.1 200 OK\r\ncontent-type: application/json\r\ncontent-length: {}\r\nconnection: close\r\n\r\n{}",
+                        body.len(),
+                        body
+                    );
+                    let _ = tls.write_all(resp.as_bytes()).await;
+                    let _ = tls.shutdown().await;
+                }
+            });
+        }
+    });
+    format!("https://{addr}")
+}
+
+fn tag_for(url: &str) -> String {
+    url.rsplit(':').next().unwrap_or("0").to_string()
+}
+
+#[tokio::test]
+async fn pinned_client_accepts_enrolled_cert_and_rejects_others() {
+    let server_cert = make_cert();
+    let other_cert = make_cert();
+    let url = spawn_https(&server_cert).await;
+    let tag = tag_for(&url);
+
+    let good_pin = write_pem(&format!("{tag}-good"), &server_cert.cert_pem);
+    let bad_pin = write_pem(&format!("{tag}-bad"), &other_cert.cert_pem);
+
+    // Enrolled with the server's own cert → handshake trusted → 200.
+    let good = build_client(Some(&good_pin)).unwrap();
+    let resp = good.get(format!("{url}/v1/models")).send().await;
+    assert!(resp.is_ok(), "enrolled cert must be accepted: {resp:?}");
+    assert_eq!(resp.unwrap().status(), 200);
+
+    // Enrolled with a different cert → server's cert is unexpected → reject.
+    let bad = build_client(Some(&bad_pin)).unwrap();
+    assert!(
+        bad.get(format!("{url}/v1/models")).send().await.is_err(),
+        "unexpected cert must be rejected"
+    );
+
+    // No enrollment (default platform roots) → self-signed cert untrusted.
+    let default = build_client(None).unwrap();
+    assert!(
+        default
+            .get(format!("{url}/v1/models"))
+            .send()
+            .await
+            .is_err(),
+        "un-enrolled self-signed cert must be rejected by default roots"
+    );
+}
+
+#[tokio::test]
+async fn poller_excludes_cortex_with_unexpected_cert() {
+    let server_cert = make_cert();
+    let other_cert = make_cert();
+    let url = spawn_https(&server_cert).await;
+    let tag = tag_for(&url);
+
+    let good_pin = write_pem(&format!("{tag}-pgood"), &server_cert.cert_pem);
+    let bad_pin = write_pem(&format!("{tag}-pbad"), &other_cert.cert_pem);
+
+    // Cortex A enrolled correctly → reachable. Cortex B enrolled with the
+    // wrong cert → TLS handshake fails → excluded.
+    let cfg = RouterConfig {
+        cortexes: vec![
+            CortexEndpoint {
+                name: "good".into(),
+                endpoint: url.clone(),
+                region: None,
+                tls_ca: Some(good_pin),
+            },
+            CortexEndpoint {
+                name: "bad".into(),
+                endpoint: url.clone(),
+                region: None,
+                tls_ca: Some(bad_pin),
+            },
+        ],
+        ..Default::default()
+    };
+    let state = RouterState::from_config(&cfg);
+    poll_once(&state).await;
+
+    let topo = state.topology.read().await;
+    assert!(
+        topo["good"].reachable,
+        "correctly-enrolled cortex reachable"
+    );
+    assert!(
+        !topo["bad"].reachable,
+        "cortex presenting an unexpected cert is excluded"
+    );
+}
+
+#[tokio::test]
+async fn misconfigured_pin_disables_cortex_fail_closed() {
+    // A `tls_ca` pointing at a nonexistent file must NOT fall back to an
+    // unpinned client — the cortex is disabled entirely.
+    let cfg = RouterConfig {
+        cortexes: vec![
+            CortexEndpoint {
+                name: "broken".into(),
+                endpoint: "https://127.0.0.1:1".into(),
+                region: None,
+                tls_ca: Some("/no/such/anchor.pem".into()),
+            },
+            CortexEndpoint {
+                name: "plain".into(),
+                endpoint: "http://127.0.0.1:1".into(),
+                region: None,
+                tls_ca: None,
+            },
+        ],
+        ..Default::default()
+    };
+    let state = RouterState::from_config(&cfg);
+    assert!(
+        state.client_for("broken").is_none(),
+        "a cortex with an unloadable pin is disabled (fail closed)"
+    );
+    assert!(
+        state.client_for("plain").is_some(),
+        "an un-pinned cortex still gets a client"
+    );
+}
+
+#[test]
+fn build_client_rejects_garbage_pem() {
+    let path = write_pem(
+        "garbage",
+        "-----BEGIN CERTIFICATE-----\nnope\n-----END CERTIFICATE-----",
+    );
+    assert!(build_client(Some(&path)).is_err());
+}

crates/helexa-router/tests/topology.rs

@@ -9,7 +9,7 @@ use axum::routing::get;
 use axum::{Json, Router};
 use helexa_router::config::{CortexEndpoint, RouterConfig};
 use helexa_router::poller::{POLL_FAILURE_THRESHOLD, poll_once};
-use helexa_router::state::RouterState;
+use helexa_router::state::{RouterState, entry_feasible};
 use serde_json::{Value, json};
 use std::sync::Arc;
 use std::sync::atomic::{AtomicBool, Ordering};
@@ -82,6 +82,8 @@ fn state_for(name: &str, endpoint: &str) -> RouterState {
         cortexes: vec![CortexEndpoint {
             name: name.into(),
             endpoint: endpoint.into(),
+            region: None,
+            tls_ca: None,
         }],
         ..Default::default()
     };
@@ -102,11 +104,12 @@ async fn poll_builds_live_topology() {
     assert!(c1.last_poll.is_some());
     assert_eq!((c1.healthy_nodes, c1.total_nodes), (2, 3));
 
-    // Loaded model: loaded + feasible. Catalogue-only model: feasible only.
+    // Loaded model: loaded + feasible. Catalogue-only model: feasible only
+    // (not loaded, but feasible_on non-empty).
     let coder = c1.models.get("Qwen/Qwen3-Coder-30B").unwrap();
-    assert!(coder.loaded && coder.feasible);
+    assert!(coder.loaded && entry_feasible(coder));
     let vl = c1.models.get("Qwen/Qwen3-VL-8B").unwrap();
-    assert!(!vl.loaded && vl.feasible);
+    assert!(!vl.loaded && entry_feasible(vl));
     drop(topo);
 
     // The routing helper sees both serveable models on the reachable cortex.

helexa-router.example.toml

@@ -17,14 +17,22 @@ listen = "0.0.0.0:8088"
 # -- Downstream cortexes -------------------------------------------------
 # Each [[cortexes]] entry is an operator-run cortex the router may dispatch
 # to. The router forwards the client's bearer verbatim (auth stays at
-# cortex) and routes on capacity. Outbound TLS to each cortex is verified.
+# cortex) and routes on capacity (preferring matching `region`).
 #
-# The skeleton only loads this list; capacity/catalogue polling and
-# capacity-aware dispatch arrive in later issues.
+# Outbound TLS pinning (optional): set `tls_ca` to a PEM trust anchor that
+# enrols this cortex — the CA (or self-signed cert) its TLS cert must chain
+# to. The router then trusts ONLY that anchor for this cortex (platform
+# roots disabled), so the router->cortex hop (which carries the client's
+# bearer) reaches the cert you expect and a rogue endpoint presenting any
+# other cert is rejected at the handshake. A cortex whose `tls_ca` fails to
+# load is disabled (fail closed). Omit `tls_ca` for a publicly-trusted cert
+# or plaintext http:// on a private (e.g. WireGuard) network.
 
 # [[cortexes]]
 # name = "lair-cafe"
 # endpoint = "https://cortex.lair.cafe"
+# region = "eu-west"
+# tls_ca = "/etc/helexa-router/pins/lair-cafe.pem"
 
 # [[cortexes]]
 # name = "example-operator"