fix(electron): make the packaged Windows build pass the #7592 cold-restart smoke (#11443)

Validated in a combined 3-PR batch worktree off release/v3.8.51 tip.
- Focused test: electron-smoke-script.test.ts — part of batch's 165/165 node:test run
- typecheck:core, file-size, changelog-integrity, complexity, cognitive-complexity, check:docs-counts-sync — all OK
- Full-repo lint: 228 pre-existing dashboard react-hooks/* findings, unrelated to this diff

Real hardware validation on a fresh packaged Windows build (Hard Rule #18) surfacing and fixing 5 genuine defects (GNU-tar drive-letter parsing, missing asar file, electron-builder's node_modules extraResources drop, USERPROFILE-derived userData path, unreachable driver-log assertion) is exactly the kind of investigation this repo needs more of. Thank you.

scripts/dev/smoke-electron-packaged.mjs

@@ -360,7 +360,12 @@ function isInsideDir(parentDir, candidateDir) {
   return candidate === parent || candidate.startsWith(parent + sep);
 }
 
-async function ensureSmokeEnvDirs(smokeEnv, dataDir) {
+export async function ensureSmokeEnvDirs(smokeEnv, dataDir, { currentPlatform = platform() } = {}) {
+  // The win32 branches below must key off the SMOKE TARGET's platform, not the
+  // host's: tests (and any future cross-platform dry-run) inject a win32-shaped
+  // smokeEnv while running on a Linux CI host, and branching on the host
+  // platform() there silently skipped the USERPROFILE/APPDATA userData tree —
+  // exactly what this function exists to pre-create (#7592).
   const dirNames = [
     "DATA_DIR",
     "HOME",
@@ -383,11 +388,21 @@ async function ensureSmokeEnvDirs(smokeEnv, dataDir) {
   // On Windows, Electron derives its userData from APPDATA/<productName>.
   // requestSingleInstanceLock() runs synchronously at module load and
   // fails silently if the directory doesn't exist yet — causing exit(0).
-  if (platform() === "win32" && smokeEnv.APPDATA) {
+  if (currentPlatform === "win32" && smokeEnv.APPDATA) {
     for (const subdir of ["omniroute-desktop", "OmniRoute", "omniroute"]) {
       dirs.push(join(smokeEnv.APPDATA, subdir));
     }
   }
+  // Electron resolves the Roaming profile from %USERPROFILE%\AppData\Roaming
+  // (USERPROFILE takes precedence over the APPDATA env var) and the path
+  // service throws — rather than creates — when that directory is missing,
+  // which makes requestSingleInstanceLock() return false and the app exit(0)
+  // before app.whenReady(). Pre-create the derived tree as well.
+  if (currentPlatform === "win32" && smokeEnv.USERPROFILE) {
+    for (const subdir of ["omniroute-desktop", "OmniRoute", "omniroute"]) {
+      dirs.push(join(smokeEnv.USERPROFILE, "AppData", "Roaming", subdir));
+    }
+  }
 
   await Promise.all(dirs.map((dir) => mkdir(dir, { recursive: true })));
 }
@@ -506,7 +521,14 @@ async function waitForReady({ logs, smokeUrl, timeoutMs, settleMs, exitState })
  * by the single-launch path and the cold-restart (two-launch) path so both
  * exercise identical spawn/readiness/shutdown behavior.
  */
-async function launchAndCollectLogs({ appExecutable, smokeUrl, dataDir, timeoutMs, settleMs, streamLogs }) {
+async function launchAndCollectLogs({
+  appExecutable,
+  smokeUrl,
+  dataDir,
+  timeoutMs,
+  settleMs,
+  streamLogs,
+}) {
   const smokeEnv = buildSmokeEnv({ dataDir });
   await assertPortIsFree(smokeUrl);
   await ensureSmokeEnvDirs(smokeEnv, dataDir);
@@ -568,7 +590,14 @@ async function main() {
     !process.env.ELECTRON_SMOKE_DATA_DIR && process.env.ELECTRON_SMOKE_KEEP_DATA !== "1";
 
   try {
-    await launchAndCollectLogs({ appExecutable, smokeUrl, dataDir, timeoutMs, settleMs, streamLogs });
+    await launchAndCollectLogs({
+      appExecutable,
+      smokeUrl,
+      dataDir,
+      timeoutMs,
+      settleMs,
+      streamLogs,
+    });
 
     if (!coldRestart) return;