fix: save and load new armor system fields properly

- _get_current_config now includes new armor fields
- to_dict properly serializes current_armor_decay as string
- from_dict properly deserializes new armor fields
- _set_config restores new armor fields when loading
- Armor decay now flows from LoadoutManager to session

ui/loadout_manager.py

@@ -441,6 +441,26 @@ class LoadoutConfig:
             else:
                 data['equipped_armor'] = None
 
+            # Handle new armor system fields
+            if 'current_armor_protection' in data and data['current_armor_protection']:
+                data['current_armor_protection'] = ProtectionProfile.from_dict(data['current_armor_protection'])
+            else:
+                data['current_armor_protection'] = ProtectionProfile()
+            
+            if 'current_armor_pieces' in data and data['current_armor_pieces']:
+                from core.armor_system import ArmorPiece
+                data['current_armor_pieces'] = [ArmorPiece.from_dict(p) for p in data['current_armor_pieces']]
+            else:
+                data['current_armor_pieces'] = []
+            
+            if 'current_armor_decay' in data:
+                try:
+                    data['current_armor_decay'] = Decimal(data['current_armor_decay'])
+                except:
+                    data['current_armor_decay'] = Decimal("0")
+            else:
+                data['current_armor_decay'] = Decimal("0")
+
             # Handle legacy configs
             if 'heal_name' not in data:
                 data['heal_name'] = '-- Custom --'
@@ -2186,6 +2206,11 @@ class LoadoutManagerDialog(QDialog):
             shots_per_hour=3600,  # Default, no longer in UI
             hits_per_hour=720,    # Default, no longer in UI
             heals_per_hour=60,    # Default, no longer in UI
+            # New armor system fields
+            current_armor_set_name=self.current_armor_set_name if hasattr(self, 'current_armor_set_name') else "None",
+            current_armor_pieces=self.current_armor_pieces if hasattr(self, 'current_armor_pieces') else [],
+            current_armor_protection=self.current_armor_protection if hasattr(self, 'current_armor_protection') else ProtectionProfile(),
+            current_armor_decay=self.current_armor_decay if hasattr(self, 'current_armor_decay') else Decimal("0"),
         )
 
     def _set_config(self, config: LoadoutConfig):
@@ -2232,6 +2257,16 @@ class LoadoutManagerDialog(QDialog):
             # Legacy or empty
             self._on_clear_armor()
 
+        # Restore new armor system fields
+        if hasattr(config, 'current_armor_set_name'):
+            self.current_armor_set_name = config.current_armor_set_name
+        if hasattr(config, 'current_armor_pieces'):
+            self.current_armor_pieces = config.current_armor_pieces
+        if hasattr(config, 'current_armor_protection'):
+            self.current_armor_protection = config.current_armor_protection
+        if hasattr(config, 'current_armor_decay'):
+            self.current_armor_decay = config.current_armor_decay
+
         self._update_armor_summary()
 
         # Healing

ui/main_window.py

@@ -949,18 +949,29 @@ class MainWindow(QMainWindow):
         loadout_info = getattr(self, '_session_loadout_info', None)
         loadout_name = loadout_info.get('name', 'Default') if loadout_info else "Default"
 
+        # Get cost data from session loadout
+        cost_per_shot = getattr(self, '_session_cost_per_shot', Decimal('0'))
+        cost_per_hit = getattr(self, '_session_cost_per_hit', Decimal('0'))
+        cost_per_heal = getattr(self, '_session_cost_per_heal', Decimal('0'))
+
         self.hud.start_session(
             weapon=weapon_name,
             armor=armor_name,
             fap=healing_name,
             loadout=loadout_name,
             weapon_dpp=weapon_dpp,
-            weapon_cost_per_hour=weapon_cost_per_hour
+            weapon_cost_per_hour=weapon_cost_per_hour,
+            cost_per_shot=cost_per_shot,
+            cost_per_hit=cost_per_hit,
+            cost_per_heal=cost_per_heal
         )
 
-        # Set up cost tracker if loadout selected
+        # Set up cost tracker if loadout selected (database-based only)
-        if loadout_info and loadout_info.get('id'):
+        if loadout_info and loadout_info.get('id') and loadout_info.get('source') == 'db':
             self._setup_session_cost_tracker(loadout_info)
+        else:
+            # For JSON-based loadouts, use manual cost tracking based on extracted values
+            self.log_info("CostTracker", "Using manual cost tracking for file-based loadout")
 
         self.log_info("HUD", f"HUD shown - Weapon: {weapon_name}, Armor: {armor_name}, Healing: {healing_name}, Loadout: {loadout_name}")
 
@@ -1249,12 +1260,24 @@ class MainWindow(QMainWindow):
             self._session_weapon_name = loadout_data.get('weapon_name', 'Unknown')
             self._session_armor_name = loadout_data.get('armor_set_name', 'Unknown')
             self._session_healing_name = loadout_data.get('heal_name', 'Unknown')
+            
+            # Extract cost data for session tracking (even for JSON-based loadouts)
+            from decimal import Decimal
+            self._session_cost_per_shot = Decimal(str(loadout_data.get('weapon_decay_pec', 0))) / Decimal('100') + \
+                                          Decimal(str(loadout_data.get('weapon_ammo_pec', 0))) * Decimal('0.0001')
+            self._session_cost_per_hit = Decimal(str(loadout_data.get('armor_decay_pec', 0))) / Decimal('100')
+            self._session_cost_per_heal = Decimal(str(loadout_data.get('heal_cost_pec', 0))) / Decimal('100')
+            
+            self.log_info("SessionCosts", f"Cost/Shot: {self._session_cost_per_shot:.4f}, Cost/Hit: {self._session_cost_per_hit:.4f}, Cost/Heal: {self._session_cost_per_heal:.4f}")
         else:
             self.log_info("Session", "Starting session without loadout")
             self._session_loadout_info = None
             self._session_weapon_name = None
             self._session_armor_name = None
             self._session_healing_name = None
+            self._session_cost_per_shot = None
+            self._session_cost_per_hit = None
+            self._session_cost_per_heal = None
 
         # Now start the session
         if self.current_project: