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ROOT CAUSE FIX: PyMuPDF silently raised AttributeError when fontname=None was passed to insert_textbox. The try/except in _try_insert was swallowing the error and returning None, causing every block to be skipped via the graceful failure path. Setting fontname='helv' as the default unblocks the entire PDF translation pipeline. SMART-FIT: rewrite _write_translated_block with proper tier-fallback: - Tier 0: original bbox at original size - Tier 1: expanded horizontal - Tier 2: expanded vertical (3x original height) - Tier 3: shrink once (0.93x) - Tier 4: shrink twice (0.87x cumulative) - Tier 5: min size floor (90% for headings, 75% for body) - Tier 6: graceful skip with visible placeholder REDACTION: single redaction per block (was per sub-bbox, creating 100+ redaction rectangles per page). Now only 1 redaction per text block. FEATURE FLAG: PDF_SMART_FIT_ENABLED (default true, observation-first). METRICS: text_overflow -> format_elements_lost_total. RESULT ON REAL PDF: Before: fonts shrunk 22pt->5.6pt, hierarchy destroyed After: fonts EXACT match: [8, 11, 12, 14, 16, 22] preserved