fix(print): refine paper matching, override tracking, and settings restore

crates/ui-egui/src/app/prefs.rs

@@ -276,19 +276,29 @@ impl PdfCraftApp {
             self.always_default_view = on;
         }
         if let Some(name) = v.get("print_paper").and_then(serde_json::Value::as_str) {
-            if let Some(paper) = self.print_draft.papers.iter().position(|(n, _)| n == name) {
-                self.print_draft.paper = paper;
-            } else if let Some(paper) = pdfcraft_engine::print::PAPERS.iter().position(|(canonical, _)| *canonical == name) {
-                self.print_draft.paper = paper;
-            } else if let Some(size) = v.get("print_paper_size").and_then(|s| {
+            let saved_size = v.get("print_paper_size").and_then(|s| {
                 let w = s.get(0)?.as_f64()?;
                 let h = s.get(1)?.as_f64()?;
                 if w >= 72.0 && h >= 72.0 && w.is_finite() && h.is_finite() { Some((w, h)) } else { None }
-            }) {
+            });
+            let matched_pos = self
+                .print_draft
+                .papers
+                .iter()
+                .position(|(n, s)| n == name && saved_size.is_none_or(|sz| (s.0 - sz.0).abs() <= 1.0 && (s.1 - sz.1).abs() <= 1.0))
+                .or_else(|| {
+                    pdfcraft_engine::print::PAPERS.iter().position(|(canonical, s)| {
+                        *canonical == name && saved_size.is_none_or(|sz| (s.0 - sz.0).abs() <= 1.0 && (s.1 - sz.1).abs() <= 1.0)
+                    })
+                });
+            if let Some(paper) = matched_pos {
+                self.print_draft.paper = paper;
+                self.print_draft.paper_overridden = v.get("print_paper_overridden").and_then(serde_json::Value::as_bool).unwrap_or(true);
+            } else if let Some(size) = saved_size {
                 self.print_draft.papers.push((name.to_string(), size));
                 self.print_draft.paper = self.print_draft.papers.len() - 1;
+                self.print_draft.paper_overridden = v.get("print_paper_overridden").and_then(serde_json::Value::as_bool).unwrap_or(true);
             }
-            self.print_draft.paper_overridden = v.get("print_paper_overridden").and_then(serde_json::Value::as_bool).unwrap_or(true);
         }
         if let Some(on) = v["highlight_fields"].as_bool() {
             self.view_defaults.highlight_fields = on;

crates/ui-egui/src/workflows/print_ui.rs

@@ -172,7 +172,7 @@ impl PdfCraftApp {
             ..keep
         };
         self.print_draft.update_printer_papers();
-        if !picked && !self.print_draft.paper_overridden {
+        if !self.print_draft.paper_overridden {
             self.print_draft.auto_select_default_paper();
         }
         self.dialog = Some(crate::Dialog::Print);

crates/ui-egui/src/workflows/print_ui/body.rs

@@ -245,7 +245,7 @@ pub(crate) fn body(
                         }
                     }
                 });
-                if d.paper != before {
+                if paper_clicked || d.paper != before {
                     d.paper_overridden = true;
                 }
                 // Label stock gets the label layout (cut, turned upright, fitted).

crates/ui-egui/src/workflows/print_ui/draft.rs

@@ -168,7 +168,7 @@ impl PrintDraft {
 
     /// Refresh `self.papers` with driver-reported media sizes, preserving the current selection.
     pub fn update_printer_papers(&mut self) {
-        let before_label_name = self.paper_before_label.and_then(|idx| self.papers.get(idx).map(|p| p.0.clone()));
+        let before_label = self.paper_before_label.and_then(|idx| self.papers.get(idx).cloned());
         let mut papers = default_papers();
         if let Some(ref printer) = self.printer {
             let detected = spool::printer_papers(printer);
@@ -188,7 +188,9 @@ impl PrintDraft {
         let current_name = self.paper_name().to_string();
         let current_size = self.paper_size();
         self.papers = papers;
-        if let Some(pos) = self.papers.iter().position(|(n, _)| n == &current_name) {
+        if let Some(pos) =
+            self.papers.iter().position(|(n, s)| n == &current_name && (s.0 - current_size.0).abs() <= 0.5 && (s.1 - current_size.1).abs() <= 0.5)
+        {
             self.paper = pos;
         } else if let Some(pos) = self.papers.iter().position(|(_, s)| (s.0 - current_size.0).abs() <= 0.5 && (s.1 - current_size.1).abs() <= 0.5) {
             self.paper = pos;
@@ -196,7 +198,16 @@ impl PrintDraft {
             self.papers.push((current_name, current_size));
             self.paper = self.papers.len() - 1;
         }
-        self.paper_before_label = before_label_name.and_then(|name| self.papers.iter().position(|(n, _)| n == &name));
+        self.paper_before_label = before_label.map(|(name, size)| {
+            if let Some(pos) = self.papers.iter().position(|(n, s)| n == &name && (s.0 - size.0).abs() <= 0.5 && (s.1 - size.1).abs() <= 0.5) {
+                pos
+            } else if let Some(pos) = self.papers.iter().position(|(_, s)| (s.0 - size.0).abs() <= 0.5 && (s.1 - size.1).abs() <= 0.5) {
+                pos
+            } else {
+                self.papers.push((name, size));
+                self.papers.len() - 1
+            }
+        });
     }
 
     /// Auto-select the printer's configured default paper (from DEVMODE / driver settings).

crates/ui-egui/tests/it/print.rs

@@ -796,6 +796,15 @@ fn paper_choice_survives_cancel_and_settings_restore() {
     app.restore(&saved);
     let expected = pdfcraft_ui_egui::PrintDraft { paper: a4, paper_overridden: true, ..Default::default() };
     assert_eq!(app.print_draft, expected, "no other print preference becomes persistent");
+
+    // Default draft without override round-trips with paper_overridden remaining false.
+    let default_app = PdfCraftApp::new();
+    let default_saved = default_app.persist();
+    let default_json: serde_json::Value = serde_json::from_str(&default_saved).unwrap();
+    assert_eq!(default_json["print_paper_overridden"], false);
+    let mut restored_default = PdfCraftApp::new();
+    restored_default.restore(&default_saved);
+    assert!(!restored_default.print_draft.paper_overridden);
     let mut restarted = harness_with_settings(Some(saved));
     assert!(restarted.state_mut().execute("print.dialog"));
     restarted.run_steps(3);