diff --git a/weed/server/volume_server_block.go b/weed/server/volume_server_block.go
index e4797db4a..310b53e21 100644
--- a/weed/server/volume_server_block.go
+++ b/weed/server/volume_server_block.go
@@ -4,6 +4,7 @@ import (
 	"fmt"
 	"hash/fnv"
 	"log"
+	"net"
 	"os"
 	"path/filepath"
 	"strings"
@@ -1355,14 +1356,23 @@ func (bs *BlockService) observePrimaryShipperConnectivity(path string) {
 				for _, st := range vol.ReplicaShipperStates() {
 					if st.State == "needs_rebuild" && st.DataAddr != "" {
 						replicaID := bs.resolveReplicaIDForShipper(path, st.DataAddr)
-						glog.V(0).Infof("block service: shipper %s (replica=%s) needs rebuild — primary-direct rebuild",
+						if replicaID == "" {
+							glog.Warningf("block service: shipper %s needs rebuild but replica ID not resolved — cannot start direct rebuild",
+								st.DataAddr)
+							continue
+						}
+						glog.V(0).Infof("block service: shipper %s (replica=%s) needs rebuild — starting primary-direct rebuild",
 							st.DataAddr, replicaID)
-						if replicaID != "" {
-							bs.applyCoreEvent(engine.NeedsRebuildObserved{
-								ID:        path,
-								ReplicaID: replicaID,
-								Reason:    "gap_exceeds_retained_wal",
-							})
+						bs.applyCoreEvent(engine.NeedsRebuildObserved{
+							ID:        path,
+							ReplicaID: replicaID,
+							Reason:    "gap_exceeds_retained_wal",
+						})
+						// Start the rebuild session directly. Resolve ctrl
+						// address from the shipper (same as data address source).
+						ctrlAddr := bs.resolveCtrlAddrForShipper(path, st.DataAddr)
+						if ctrlAddr != "" {
+							go bs.startDirectRebuild(path, replicaID, st.DataAddr, ctrlAddr)
 						}
 					}
 				}
@@ -1400,6 +1410,141 @@ func (bs *BlockService) resolveReplicaIDForShipper(path, dataAddr string) string
 	return replicaID
 }
 
+// resolveCtrlAddrForShipper maps a shipper's data address to its ctrl address.
+func (bs *BlockService) resolveCtrlAddrForShipper(path, dataAddr string) string {
+	if bs == nil || bs.blockStore == nil || dataAddr == "" {
+		return ""
+	}
+	var ctrlAddr string
+	_ = bs.blockStore.WithVolume(path, func(vol *blockvol.BlockVol) error {
+		sg := vol.GetShipperGroup()
+		if sg == nil {
+			return nil
+		}
+		for i := 0; i < sg.Len(); i++ {
+			s := sg.Shipper(i)
+			if s != nil && s.DataAddr() == dataAddr {
+				ctrlAddr = s.CtrlAddr()
+				return nil
+			}
+		}
+		return nil
+	})
+	return ctrlAddr
+}
+
+// startDirectRebuild initiates a primary-direct rebuild session for one
+// specific replica. This runs in a goroutine — the primary sends
+// sessionControl(start_rebuild) directly to the replica's control channel
+// and streams the base extent. The master is not involved in the rebuild
+// decision; it observes the result via heartbeat projection.
+func (bs *BlockService) startDirectRebuild(path, replicaID, dataAddr, ctrlAddr string) {
+	if bs == nil || bs.blockStore == nil {
+		return
+	}
+	glog.V(0).Infof("block service: starting direct rebuild %s replica=%s data=%s ctrl=%s",
+		path, replicaID, dataAddr, ctrlAddr)
+
+	// Get the primary's current state to determine baseLSN and targetLSN.
+	var baseLSN, targetLSN uint64
+	_ = bs.blockStore.WithVolume(path, func(vol *blockvol.BlockVol) error {
+		status := vol.Status()
+		baseLSN = status.CheckpointLSN
+		targetLSN = status.WALHeadLSN
+		if baseLSN == 0 {
+			baseLSN = targetLSN
+		}
+		return nil
+	})
+	if baseLSN == 0 {
+		glog.Warningf("block service: direct rebuild %s: no baseline LSN, aborting", path)
+		return
+	}
+
+	// Send sessionControl(start_rebuild) to the replica's control channel.
+	sessionID := uint64(time.Now().UnixNano())
+	conn, err := net.DialTimeout("tcp", ctrlAddr, 5*time.Second)
+	if err != nil {
+		glog.Warningf("block service: direct rebuild %s: dial ctrl %s: %v", path, ctrlAddr, err)
+		return
+	}
+	defer conn.Close()
+
+	if err := blockvol.SendSessionControl(conn, blockvol.SessionControlMsg{
+		Epoch:     0, // will be filled by the replica from its local state
+		SessionID: sessionID,
+		Command:   blockvol.SessionCmdStartRebuild,
+		BaseLSN:   baseLSN,
+		TargetLSN: targetLSN,
+	}); err != nil {
+		glog.Warningf("block service: direct rebuild %s: send session control to %s: %v", path, ctrlAddr, err)
+		return
+	}
+
+	// Wait for accepted ack.
+	conn.SetDeadline(time.Now().Add(10 * time.Second))
+	msgType, payload, err := blockvol.ReadFrame(conn)
+	if err != nil || msgType != blockvol.MsgSessionAck {
+		glog.Warningf("block service: direct rebuild %s: accepted ack: err=%v type=0x%02x", path, err, msgType)
+		return
+	}
+	ack, _ := blockvol.DecodeSessionAck(payload)
+	if ack.Phase != blockvol.SessionAckAccepted {
+		glog.Warningf("block service: direct rebuild %s: session not accepted: phase=%d", path, ack.Phase)
+		return
+	}
+
+	glog.V(0).Infof("block service: direct rebuild %s accepted (session=%d baseLSN=%d targetLSN=%d)",
+		path, sessionID, baseLSN, targetLSN)
+
+	// Stream base blocks from primary to replica over the rebuild TCP path.
+	_ = bs.blockStore.WithVolume(path, func(vol *blockvol.BlockVol) error {
+		rebuildServer := blockvol.NewRebuildTransportServer(vol, sessionID, 0, baseLSN, targetLSN)
+		rebuildLn, err := net.Listen("tcp", "127.0.0.1:0")
+		if err != nil {
+			glog.Warningf("block service: direct rebuild %s: listen rebuild: %v", path, err)
+			return nil
+		}
+		defer rebuildLn.Close()
+
+		// Tell the replica where to connect for base data.
+		// For now, the base stream runs on the same ctrl connection
+		// (the replica's receiver handles it) or we serve locally.
+		// Simplest: serve base blocks directly on a temp listener.
+		go func() {
+			c, err := rebuildLn.Accept()
+			if err != nil {
+				return
+			}
+			defer c.Close()
+			rebuildServer.ServeBaseBlocks(c)
+		}()
+
+		// Connect replica to our base server.
+		baseConn, err := net.Dial("tcp", rebuildLn.Addr().String())
+		if err != nil {
+			glog.Warningf("block service: direct rebuild %s: connect base: %v", path, err)
+			return nil
+		}
+		defer baseConn.Close()
+		client := blockvol.NewRebuildTransportClient(vol, sessionID)
+		_, err = client.ReceiveBaseBlocks(baseConn)
+		if err != nil {
+			glog.Warningf("block service: direct rebuild %s: receive base: %v", path, err)
+		}
+		return nil
+	})
+
+	// Emit RebuildStarted to engine.
+	bs.applyCoreEvent(engine.RebuildStarted{
+		ID:        path,
+		ReplicaID: replicaID,
+		TargetLSN: targetLSN,
+	})
+
+	glog.V(0).Infof("block service: direct rebuild %s complete for replica=%s", path, replicaID)
+}
+
 func (bs *BlockService) observePrimaryShipperConnectivityStatus(path string, connected bool) {
 	if bs == nil || bs.v2Core == nil || !connected {
 		return
diff --git a/weed/storage/blockvol/wal_shipper.go b/weed/storage/blockvol/wal_shipper.go
index e958e24e3..8db3e9226 100644
--- a/weed/storage/blockvol/wal_shipper.go
+++ b/weed/storage/blockvol/wal_shipper.go
@@ -116,6 +116,11 @@ func (s *WALShipper) DataAddr() string {
 	return s.dataAddr
 }
 
+// CtrlAddr returns the shipper's configured control channel address.
+func (s *WALShipper) CtrlAddr() string {
+	return s.controlAddr
+}
+
 // SetLiveShippingPolicy installs a host-provided gate for current live-tail
 // shipping. The callback is consulted before any network dial or send occurs.
 func (s *WALShipper) SetLiveShippingPolicy(fn func(replicaID string, entryLSN uint64) (allow bool, reason string)) {