fix(ci): resolve deployment error for auth-nextjs-demo on Vercel

[halvaradop]

Description

This pull request fixes the error encountered when deploying the auth-nextjs-demo application on Vercel. The issue is recent and does not have a clear or well-documented root cause, which made it difficult to diagnose initially.

Several deployment attempts were made on Vercel with different local changes, but none of them resolved the problem. The build logs consistently indicated that the failure occurred during the build process of the @aura-stack/auth package.

After further investigation, the issue was traced to incorrect Zod schema inference during the TypeScript declaration (dts) build step. Specifically, some schemas were being typed as incompatible ZodObject instances, and search parameters were being accessed as strongly typed properties instead of through the URLSearchParams API.

Error Logs

@aura-stack/auth:build: src/actions/callback/callback.ts(17,13): error TS2740: Type 'ZodObject<{ oauth: ZodEnum<{ [x: string & Record<never, never>]: string & Record<never, never>; github: "github"; bitbucket: "bitbucket"; figma: "figma"; discord: "discord"; gitlab: "gitlab"; spotify: "spotify"; x: "x"; strava: "strava"; mailchimp: "mailchimp"; }>; }, $strip>' is missing the following properties from type 'ZodObject<any, UnknownKeysParam, ZodTypeAny, { [x: string]: any; }, { [x: string]: any; }>': _cached, _getCached, _parse, nonstrict, and 13 more.
@aura-stack/auth:build: src/actions/callback/callback.ts(20,13): error TS2740: Type 'ZodObject<{ state: ZodString; code: ZodString; }, $strip>' is missing the following properties from type 'ZodObject<any, UnknownKeysParam, ZodTypeAny, { [x: string]: any; }, { [x: string]: any; }>': _cached, _getCached, _parse, nonstrict, and 13 more.
@aura-stack/auth:build: src/actions/callback/callback.ts(43,33): error TS2339: Property 'code' does not exist on type 'URLSearchParams'.
@aura-stack/auth:build: src/actions/callback/callback.ts(43,39): error TS2339: Property 'state' does not exist on type 'URLSearchParams'.
@aura-stack/auth:build: Error: error occurred in dts build

Note

This pull request will be merged. However, it is possible that the current solution may introduce unexpected behavior. I will continue monitoring the codebase closely and watch for any side effects or regressions that may arise as a result of these changes.

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Project	Deployment	Review	Updated (UTC)
auth-nextjs-demo	Ready	Preview, Comment	Jan 21, 2026 8:19pm

1 Skipped Deployment

Project	Deployment	Review	Updated (UTC)
auth	Skipped		Jan 21, 2026 8:19pm

[halvaradop]

Root Cause Analysis and Resolution

After spending a significant amount of time investigating the root cause of the build error, the issue was finally identified.

The problem was primarily caused by a Zod version mismatch between the core package and the tanstack-start example application.

What Happened

• The @aura-stack/auth core package was expected to use zod@^4.1.11.
• However, for an unknown reason, the core package was resolving zod@^4.3.5, which was defined in the apps/tanstack-start package.
• This mismatch caused TypeScript and Zod types to become incompatible during the dts build process, leading to confusing and misleading errors.

Initial Attempted Fix

To solve the issue, Zod was added to the pnpm catalogs with the expected version:

^4.1.11

However:

• pnpm still resolved and installed zod@^4.3.5 instead of the catalog-defined version.
• To force consistency, the version was pinned explicitly to 4.1.11.
• This fixed the dependency resolution, but introduced a new issue:
  • The core package failed to build its type declarations.
  • The build crashed with a JavaScript heap out-of-memory / stack overflow error.

Final Solution

The stable and correct solution was:

• Remove Zod from pnpm catalogs
• Explicitly use the same Zod version (^4.1.11) in both:
  • packages/core
  • apps/tanstack-start

This approach aligns with the version already used by @aura-stack/router, ensuring consistency across the monorepo and avoiding subtle type incompatibilities.

Why ^4.1.11?
@aura-stack/router already depends on zod@^4.1.11. Using the same version prevents future mismatches and reduces maintenance overhead

Related Files

Core package Zod dependency

auth/packages/core/package.json

Line 63 in 12fd0b6

"zod": "^4.1.12"

TanStack Start example Zod dependency

auth/apps/tanstack-start/package.json

Line 35 in 12fd0b6

"zod": "^4.3.5"