From 92eb282310e909ffb90899349886516761192788 Mon Sep 17 00:00:00 2001
From: src-opn <gh2@mcadam.io>
Date: Fri, 29 May 2026 09:15:44 -0700
Subject: [PATCH] fix(app): bound e2e health checks with per-request timeout

waitForHealthy polled /global/health with no per-request timeout, so a
single fetch to a not-yet-listening opencode port could block on the
OS-level TCP connect timeout and blow past the 10s budget (the loop only
re-checks the deadline between awaits). This caused recurring ~5-minute
"Timed out waiting for /global/health: fetch failed" failures on the
macOS-14 CI runner.

Bound each request with AbortSignal.timeout, raise the overall budget for
slow CI cold starts, and capture server stdout + exit info so future
failures are diagnosable instead of showing empty stderr.
---
 apps/app/scripts/_util.mjs          | 30 +++++++++++++++++++++++++----
 apps/app/scripts/browser-entry.mjs  |  2 ++
 apps/app/scripts/e2e.mjs            |  2 ++
 apps/app/scripts/fs-engine.mjs      | 10 +++++++++-
 apps/app/scripts/session-switch.mjs |  2 ++
 5 files changed, 41 insertions(+), 5 deletions(-)

diff --git a/apps/app/scripts/_util.mjs b/apps/app/scripts/_util.mjs
index aa6bcc0926..76369d1a97 100644
--- a/apps/app/scripts/_util.mjs
+++ b/apps/app/scripts/_util.mjs
@@ -59,7 +59,7 @@ export async function spawnOpencodeServe({
 
   const child = spawn("opencode", args, {
     cwd,
-    stdio: ["ignore", "ignore", "pipe"],
+    stdio: ["ignore", "pipe", "pipe"],
     env: {
       ...process.env,
       // Make it explicit we're a non-TUI client.
@@ -69,13 +69,20 @@ export async function spawnOpencodeServe({
 
   const baseUrl = `http://${hostname}:${port}`;
 
-  // If the process dies early, surface stderr.
+  // If the process dies early or never becomes healthy, surface its output so
+  // CI failures are diagnosable instead of showing an empty stderr.
   let stderr = "";
   child.stderr.setEncoding("utf8");
   child.stderr.on("data", (chunk) => {
     stderr += chunk;
   });
 
+  let stdout = "";
+  child.stdout.setEncoding("utf8");
+  child.stdout.on("data", (chunk) => {
+    stdout += chunk;
+  });
+
   async function waitForExit(ms) {
     return Promise.race([
       once(child, "exit").then(() => true),
@@ -115,16 +122,31 @@ export async function spawnOpencodeServe({
     getStderr() {
       return stderr;
     },
+    getStdout() {
+      return stdout;
+    },
+    getExitInfo() {
+      return { exitCode: child.exitCode, signalCode: child.signalCode };
+    },
   };
 }
 
-export async function waitForHealthy(client, { timeoutMs = 10_000, pollMs = 250 } = {}) {
+export async function waitForHealthy(
+  client,
+  { timeoutMs = 30_000, pollMs = 250, requestTimeoutMs = 5_000 } = {},
+) {
   const start = Date.now();
   let lastError;
 
   while (Date.now() - start < timeoutMs) {
     try {
-      const health = await client.global.health();
+      // Bound each individual request: a single fetch to a port that is not
+      // yet accepting connections can otherwise block for the OS-level connect
+      // timeout (tens of seconds on macOS), blowing past `timeoutMs` because
+      // the loop can only re-check the deadline between awaits.
+      const health = await client.global.health({
+        signal: AbortSignal.timeout(requestTimeoutMs),
+      });
       assert.equal(health.healthy, true);
       assert.ok(typeof health.version === "string");
       return health;
diff --git a/apps/app/scripts/browser-entry.mjs b/apps/app/scripts/browser-entry.mjs
index ad71d782a9..7d0bc5d49b 100644
--- a/apps/app/scripts/browser-entry.mjs
+++ b/apps/app/scripts/browser-entry.mjs
@@ -284,6 +284,8 @@ try {
   results.ok = false;
   results.error = message;
   results.stderr = opencode?.getStderr?.() ?? "";
+  results.stdout = opencode?.getStdout?.() ?? "";
+  results.serverExit = opencode?.getExitInfo?.() ?? null;
   console.error(JSON.stringify(results, null, 2));
   process.exitCode = 1;
 } finally {
diff --git a/apps/app/scripts/e2e.mjs b/apps/app/scripts/e2e.mjs
index 79c2bbeb71..fc6f100770 100644
--- a/apps/app/scripts/e2e.mjs
+++ b/apps/app/scripts/e2e.mjs
@@ -154,6 +154,8 @@ try {
   results.ok = false;
   results.error = message;
   results.stderr = server.getStderr();
+  results.stdout = server.getStdout?.() ?? "";
+  results.serverExit = server.getExitInfo?.() ?? null;
   console.error(JSON.stringify(results, null, 2));
   process.exitCode = 1;
 } finally {
diff --git a/apps/app/scripts/fs-engine.mjs b/apps/app/scripts/fs-engine.mjs
index 7fb044ffdf..89835fcccd 100644
--- a/apps/app/scripts/fs-engine.mjs
+++ b/apps/app/scripts/fs-engine.mjs
@@ -47,7 +47,15 @@ try {
   );
 } catch (e) {
   const message = e instanceof Error ? e.message : String(e);
-  console.error(JSON.stringify({ ok: false, error: message, stderr: server.getStderr() }));
+  console.error(
+    JSON.stringify({
+      ok: false,
+      error: message,
+      stderr: server.getStderr(),
+      stdout: server.getStdout?.() ?? "",
+      serverExit: server.getExitInfo?.() ?? null,
+    }),
+  );
   process.exitCode = 1;
 } finally {
   await server.close();
diff --git a/apps/app/scripts/session-switch.mjs b/apps/app/scripts/session-switch.mjs
index 694f65cca6..cc6192cd07 100644
--- a/apps/app/scripts/session-switch.mjs
+++ b/apps/app/scripts/session-switch.mjs
@@ -144,6 +144,8 @@ try {
   results.ok = false;
   results.error = message;
   results.stderr = server.getStderr();
+  results.stdout = server.getStdout?.() ?? "";
+  results.serverExit = server.getExitInfo?.() ?? null;
   console.error(JSON.stringify(results, null, 2));
   process.exitCode = 1;
 } finally {