chore: add install-flex, fix Blacksmith ARM64 CI (build tools + test timeouts), fix per-branch DB

.github/actions/setup-bun/action.yml

@@ -3,19 +3,37 @@ description: "Setup Bun with caching and install dependencies"
 runs:
   using: "composite"
   steps:
-    - name: Get baseline download URL
+    - name: Ensure build tools are available
+      if: runner.os == 'Linux'
+      shell: bash
+      # Blacksmith's ARM64 ubuntu-2404 runners ship a minimal image that is missing:
+      #   unzip        — needed by oven-sh/setup-bun to extract the downloaded bun zip
+      #   build-essential (make, g++) — needed by node-gyp to compile native addons
+      #                  (e.g. tree-sitter-powershell) during `bun install`
+      run: |
+        PKGS=()
+        command -v unzip >/dev/null 2>&1 || PKGS+=(unzip)
+        command -v make  >/dev/null 2>&1 || PKGS+=(build-essential)
+        [ ${#PKGS[@]} -gt 0 ] && sudo apt-get install -y --no-install-recommends "${PKGS[@]}"
+        true
+
+    - name: Get bun download URL
       id: bun-url
       shell: bash
       run: |
-        if [ "$RUNNER_ARCH" = "X64" ]; then
-          V=$(node -p "require('./package.json').packageManager.split('@')[1]")
-          case "$RUNNER_OS" in
-            macOS)   OS=darwin ;;
-            Linux)   OS=linux ;;
-            Windows) OS=windows ;;
-          esac
-          echo "url=https://github.com/oven-sh/bun/releases/download/bun-v${V}/bun-${OS}-x64-baseline.zip" >> "$GITHUB_OUTPUT"
-        fi
+        V=$(node -p "require('./package.json').packageManager.split('@')[1]")
+        case "$RUNNER_OS" in
+          macOS)   OS=darwin  ;;
+          Linux)   OS=linux   ;;
+          Windows) OS=windows ;;
+          *) exit 0 ;;
+        esac
+        case "$RUNNER_ARCH" in
+          X64)   ARCH=x64-baseline ;;
+          ARM64) ARCH=aarch64      ;;
+          *) exit 0 ;;
+        esac
+        echo "url=https://github.com/oven-sh/bun/releases/download/bun-v${V}/bun-${OS}-${ARCH}.zip" >> "$GITHUB_OUTPUT"
 
     - name: Setup Bun
       uses: oven-sh/setup-bun@v2

.github/workflows/test.yml

@@ -63,6 +63,24 @@ jobs:
             turbo-${{ runner.os }}-${{ hashFiles('turbo.json', '**/package.json') }}-
             turbo-${{ runner.os }}-
 
+      - name: Cache npm registry packages
+        # Plugin integration tests install @opencode-ai/plugin into fresh temp dirs
+        # using @npmcli/arborist, which fetches from the npm registry and caches
+        # tarballs in ~/.npm. Without this cache, each test does a full network
+        # download, easily hitting the 30 s bun test timeout on Blacksmith ARM64.
+        uses: actions/cache@v4
+        with:
+          path: ~/.npm
+          key: npm-${{ runner.os }}-${{ runner.arch }}-opencode-ai-plugin-${{ hashFiles('**/package.json') }}
+          restore-keys: |
+            npm-${{ runner.os }}-${{ runner.arch }}-opencode-ai-plugin-
+
+      - name: Warm npm cache for @opencode-ai/plugin
+        # Pre-populate ~/.npm so arborist can satisfy @opencode-ai/plugin from
+        # cache during plugin integration tests instead of hitting the registry.
+        if: runner.os == 'Linux'
+        run: npm install --prefix /tmp/plugin-warmup @opencode-ai/plugin
+
       - name: Run unit tests
         run: bun turbo test:ci
         env:

.opencode/sessions/chore-bolster-install.md

@@ -0,0 +1,80 @@
+# Session: Bolster Install — Blacksmith ARM64 CI Fixes
+
+**Branch**: chore/bolster-install
+**Issue**: N/A
+**Created**: 2026-04-22
+**Status**: complete — PR #11 open, awaiting merge
+
+## Goal
+Harden the `install-flex` automated installer and fix all Blacksmith ARM64 CI
+failures that were blocking the unit and e2e test jobs on the Flexion fork.
+
+## Approach
+Fix issues in layers as they surfaced during CI runs:
+1. Add `install-flex` installer script
+2. Pin `OPENCODE_CHANNEL=flex` to prevent per-branch SQLite DB fragmentation
+3. Fix missing build tools on Blacksmith ARM64 runners
+4. Fix unit test timeouts caused by arborist npm installs during tests
+5. Bump individual test timeouts that are tight on ARM64
+
+## Session Log
+- 2026-04-22: Session created
+- 2026-04-22: Added `install-flex` script (already existed on branch), fixed DB fragmentation
+- 2026-04-22: CI round 1 — fixed `unzip` missing (setup-bun)
+- 2026-04-22: CI round 2 — fixed `make`/`g++` missing (build-essential for node-gyp)
+- 2026-04-22: CI round 3 — 7 test timeouts; root-caused to `@npmcli/arborist.reify()` in tests
+- 2026-04-22: CI round 4 — 1 remaining timeout; fixed shell-loop test 3s → 15s
+- 2026-04-22: All CI jobs passing. PR updated.
+- 2026-04-22: CI round 5 — 1 new timeout; "shell rejects with BusyError when loop running" 3s → 15s
+
+## Key Decisions
+
+### `OPENCODE_CHANNEL=flex` in `install-flex`
+OpenCode bakes `InstallationChannel` from the git branch at build time and uses it
+as the SQLite DB name suffix (`opencode-<channel>.db`). Without pinning, each
+rebuild from a different branch creates a fresh empty database, losing all session
+history. Pinning to `"flex"` ensures all Flexion builds share `opencode-flex.db`.
+See: `packages/opencode/src/storage/db.ts:getChannelPath()`.
+
+### `OPENCODE_DISABLE_PLUGIN_DEPS_INSTALL` flag
+`config.ts` fires a background `@npmcli/arborist.reify()` for `@opencode-ai/plugin`
+in every `.opencode/` directory it discovers. In tests, 7 tests were timing out
+because: plugin/tool tests called `waitForDependencies()` which joined the arborist
+fiber (10–30 s per test on ARM64), and the resulting CPU saturation starved
+concurrent session/snapshot tests. The flag skips the install in tests; safe because
+bun resolves `@opencode-ai/plugin` from the workspace `node_modules` directly.
+Set unconditionally in `test/preload.ts`.
+
+### Blacksmith ARM64 runner gaps
+`blacksmith-4vcpu-ubuntu-2404` uses ARM64 and ships a minimal Ubuntu image missing:
+- `unzip` — needed by `oven-sh/setup-bun@v2` to extract the downloaded bun zip
+- `make`/`g++` (build-essential) — needed by `node-gyp` for `tree-sitter-powershell`
+Both now installed in a single `Ensure build tools are available` step in
+`.github/actions/setup-bun/action.yml` (Linux only, no-op if already present).
+
+### Test timeout bumps
+- `snapshot.test.ts` "revert handles large mixed batches": 30 s → 60 s
+  (280 files + multiple git commits/patches/reverts on ARM64)
+- `prompt-effect.test.ts` "loop waits while shell runs": 3 s → 15 s
+  (spawns a real `sleep 0.2` subprocess; ARM64 fork/exec overhead exceeds 3 s)
+- `prompt-effect.test.ts` "shell rejects with BusyError when loop running": 3 s → 15 s
+  (fiber fork + session init before `llm.wait(1)` exceeds 3 s on ARM64)
+
+## Files Changed
+- `install-flex` — `OPENCODE_CHANNEL=flex` added to build command
+- `.github/actions/setup-bun/action.yml` — build tools prereq + ARM64/X64 URL construction
+- `.github/workflows/test.yml` — npm cache + pre-warm step (unit job)
+- `packages/opencode/src/flag/flag.ts` — `OPENCODE_DISABLE_PLUGIN_DEPS_INSTALL` flag
+- `packages/opencode/src/config/config.ts` — guard arborist install with new flag
+- `packages/opencode/test/preload.ts` — set `OPENCODE_DISABLE_PLUGIN_DEPS_INSTALL=true`
+- `packages/opencode/test/snapshot/snapshot.test.ts` — 60 s timeout on 280-file test
+- `packages/opencode/test/session/prompt-effect.test.ts` — 15 s timeout on shell-loop test
+
+## Side Effects Applied Outside the Repo
+- `~/.opencode/bin/opencode` — rebuilt from this branch with `OPENCODE_CHANNEL=flex`;
+  now reports `0.0.0-flex-<timestamp>` and uses `~/.local/share/opencode/opencode-flex.db`
+
+## Next Steps
+- [ ] Merge PR #11 into flex: https://github.com/flexion/opencode/pull/11
+- [ ] After merge, other developers run `install-flex` to pick up all fixes
+- [ ] Consider periodically running `install-flex` to stay current with `flex` branch

LOCAL_AWS_SETUP.md

@@ -2,6 +2,27 @@
 
 Instructions for cloning, building, and running the Flexion fork of opencode with AWS Bedrock.
 
+## Quick Install
+
+The installer handles all steps below automatically:
+
+```bash
+curl -fsSL https://raw.githubusercontent.com/flexion/opencode/flex/install-flex | bash
+```
+
+You will be prompted for:
+- **Clone directory** (default: `~/opencode`)
+- **AWS account ID** (your personal Flexion account)
+- **Preferred AWS region** (default: `us-east-1`)
+
+Everything else — AWS SSO profile, opencode config, and the `opencode-work` shell function — is written automatically. Skip to [Usage](#4-usage) once the installer finishes.
+
+---
+
+## Manual Setup
+
+Follow these steps if you prefer to configure things yourself.
+
 ## Prerequisites
 
 - [Bun](https://bun.sh) v1.3+
@@ -46,11 +67,11 @@ Add to `~/.aws/config`:
 
 ```ini
 [profile ClaudeCodeAccess]
-sso_start_url = <your-sso-start-url>
-sso_region = <your-sso-region>
+sso_start_url  = https://identitycenter.amazonaws.com/ssoins-6684680a9b285ea2
+sso_region     = us-east-2
 sso_account_id = <your-account-id>
-sso_role_name = AdministratorAccess
-region = <your-preferred-region>
+sso_role_name  = ClaudeCodeAccess
+region         = <your-preferred-region>
 ```
 
 ### 2. Configure opencode for Bedrock
@@ -118,20 +139,24 @@ Create `~/.config/opencode/opencode.json`:
 
 ### 3. Shell alias
 
-Add to `~/.zshrc` or `~/.bashrc`:
+Add to `~/.zshrc` or `~/.bashrc` (replace `~/opencode` with your actual clone path if different):
 
 ```bash
+# ── Flexion opencode launcher ─────────────────────────────────────────────────
 opencode-work() {
   local profile="ClaudeCodeAccess"
+  local arch os
+  case "$(uname -m)" in arm64|aarch64) arch="arm64" ;; *) arch="x64" ;; esac
+  case "$(uname -s)" in Darwin) os="darwin" ;; Linux) os="linux" ;; *)
+    echo "Unsupported OS: $(uname -s)" && return 1 ;; esac
   echo "Logging in to AWS SSO ($profile)..."
   aws sso login --profile "$profile" || return 1
   eval "$(aws configure export-credentials --profile "$profile" --format env)"
-  /path/to/opencode/packages/opencode/dist/opencode-darwin-arm64/bin/opencode "${opencode_args[@]}"
+  "$HOME/opencode/packages/opencode/dist/opencode-${os}-${arch}/bin/opencode" "$@"
 }
+# ─────────────────────────────────────────────────────────────────────────────
 ```
 
-Replace `/path/to/opencode` with where you cloned the repo (e.g. `~/Code/personal/flexion-work-items/flexchat-stack/opencode`).
-
 ### 4. Usage
 
 ```bash
@@ -174,6 +199,7 @@ See [flexion/opencode#2](https://github.com/flexion/opencode/pull/2) for the ful
 | Strip reasoning from history for non-reasoning models | `packages/opencode/src/provider/transform.ts` | Removes reasoning content parts from assistant message history before sending to models with `reasoning: false` — fixes Bedrock rejections when switching from a reasoning model |
 | Exclude palmyra from reasoning variant generation | `packages/opencode/src/provider/transform.ts` | Prevents unsupported `reasoningConfig` parameters from being sent to Writer Palmyra models |
 | Local build & AWS Bedrock setup docs | `LOCAL_AWS_SETUP.md` | This file |
+| Automated installer | `install-flex` | Single-command installer for the entire setup |
 
 Full details and upstream tracking: [flexion/opencode#2](https://github.com/flexion/opencode/pull/2)