fix(ci): build API-only smoke workflows backend-only to fix dast-smoke timeouts (#7226) (#7758)

dast-smoke.yml and 3 nightly API-only smoke workflows (nightly-schemathesis,
nightly-resilience, nightly-llm-security) ran "npm run build:cli" with no
preceding full build or downloaded .build/next artifact. scripts/build/
prepublish.ts silently falls back to a full Next.js production build
(dashboard UI + ~126 leaf pages + prerender) whenever the standalone
server.js is missing, which is always the case in these jobs. That inline
full build is the actual thing varying 6-29min on GitHub-hosted runners.

These workflows only exercise API routes (schemathesis/promptfoo hit
/api/monitoring/health, /v1/chat/completions, /v1/models, /api/auth,
/api/keys) and never touch the dashboard UI, so set
OMNIROUTE_BUILD_BACKEND_ONLY=1 on their "Build CLI bundle" step — an
existing, previously-unused escape hatch (scripts/build/backendOnlyPages.mjs)
that stubs the dashboard pages before the build and restores them after,
leaving every route.ts API handler intact.

npm-publish.yml is intentionally left untouched: it legitimately ships the
full dashboard UI in the published npm package.

Regression guard: tests/unit/build/backend-only-smoke-workflows.test.ts
asserts OMNIROUTE_BUILD_BACKEND_ONLY=1/OMNIROUTE_BUILD_PROFILE=backend on
all 5 "Build CLI bundle" steps across the 4 fixed workflows, and asserts
npm-publish.yml's build step is NOT backend-only.

.github/workflows/dast-smoke.yml

@@ -27,6 +27,8 @@ jobs:
           cache: npm
       - run: npm ci
       - name: Build CLI bundle
+        env:
+          OMNIROUTE_BUILD_BACKEND_ONLY: "1"
         run: npm run build:cli
       - name: Start OmniRoute
         env:

.github/workflows/nightly-llm-security.yml

@@ -19,7 +19,9 @@ jobs:
         with: { node-version: "24", cache: npm }
       - run: npm ci
       - name: Build CLI bundle
-        env: { JWT_SECRET: ci-build-secret-with-sufficient-length-for-validation }
+        env:
+          JWT_SECRET: ci-build-secret-with-sufficient-length-for-validation
+          OMNIROUTE_BUILD_BACKEND_ONLY: "1"
         run: npm run build:cli
       - name: Start OmniRoute (block mode)
         env:
@@ -72,7 +74,9 @@ jobs:
         if: steps.gate.outputs.run == 'true'
       - name: Build CLI bundle
         if: steps.gate.outputs.run == 'true'
-        env: { JWT_SECRET: ci-build-secret-with-sufficient-length-for-validation }
+        env:
+          JWT_SECRET: ci-build-secret-with-sufficient-length-for-validation
+          OMNIROUTE_BUILD_BACKEND_ONLY: "1"
         run: npm run build:cli
       - name: Start OmniRoute
         if: steps.gate.outputs.run == 'true'

.github/workflows/nightly-resilience.yml

@@ -51,6 +51,7 @@ jobs:
       - name: Build CLI bundle
         env:
           JWT_SECRET: ci-build-secret-with-sufficient-length-for-validation
+          OMNIROUTE_BUILD_BACKEND_ONLY: "1"
         run: npm run build:cli
       - name: Start OmniRoute (background)
         env:

.github/workflows/nightly-schemathesis.yml

@@ -20,7 +20,9 @@ jobs:
         with: { node-version: "24", cache: npm }
       - run: npm ci
       - name: Build CLI bundle
-        env: { JWT_SECRET: ci-build-secret-with-sufficient-length-for-validation }
+        env:
+          JWT_SECRET: ci-build-secret-with-sufficient-length-for-validation
+          OMNIROUTE_BUILD_BACKEND_ONLY: "1"
         run: npm run build:cli
       - name: Start OmniRoute (background)
         env:

changelog.d/fixes/7226-dast-smoke-backend-only.md

@@ -0,0 +1 @@
+- fix(ci): build dast-smoke and nightly API-only smoke workflows with `OMNIROUTE_BUILD_BACKEND_ONLY=1` to skip the unused dashboard UI graph and stop the multi-minute build variance/timeouts (#7226)

tests/unit/build/backend-only-smoke-workflows.test.ts

@@ -0,0 +1,88 @@
+// Regression guard for #7226: API-only smoke/nightly workflows must build with
+// OMNIROUTE_BUILD_BACKEND_ONLY=1 so `npm run build:cli`'s fallback full build
+// (scripts/build/prepublish.ts -> build-next-isolated.mjs) skips the ~126-leaf-page
+// dashboard UI graph these workflows never exercise. Without this env var, the
+// "Build CLI bundle" step silently runs a full Next.js production build inline,
+// which is the actual source of the multi-minute variance/timeouts reported in #7226.
+//
+// npm-publish.yml is intentionally excluded: its "Build CLI bundle (standalone app)"
+// step legitimately ships the full dashboard UI in the published npm package.
+import test from "node:test";
+import assert from "node:assert/strict";
+import fs from "node:fs";
+import path from "node:path";
+import * as yaml from "js-yaml";
+
+interface WorkflowStep {
+  name?: string;
+  run?: string;
+  env?: Record<string, string>;
+  [key: string]: unknown;
+}
+
+interface WorkflowJob {
+  steps: WorkflowStep[];
+  [key: string]: unknown;
+}
+
+interface WorkflowDoc {
+  jobs: Record<string, WorkflowJob>;
+  [key: string]: unknown;
+}
+
+const WORKFLOWS_DIR = path.join(process.cwd(), ".github", "workflows");
+
+function loadWorkflow(fileName: string): WorkflowDoc {
+  const raw = fs.readFileSync(path.join(WORKFLOWS_DIR, fileName), "utf8");
+  return yaml.load(raw) as WorkflowDoc;
+}
+
+function isBackendOnly(step: WorkflowStep): boolean {
+  const env = step.env || {};
+  return env.OMNIROUTE_BUILD_BACKEND_ONLY === "1" || env.OMNIROUTE_BUILD_PROFILE === "backend";
+}
+
+// jobName: null selector means "any job" — used when a file has exactly one
+// "Build CLI bundle" step but we don't want to hardcode/duplicate the job key.
+interface Target {
+  file: string;
+  jobName: string;
+  stepName: string;
+}
+
+const TARGETS: Target[] = [
+  { file: "dast-smoke.yml", jobName: "dast-smoke", stepName: "Build CLI bundle" },
+  { file: "nightly-schemathesis.yml", jobName: "schemathesis", stepName: "Build CLI bundle" },
+  { file: "nightly-resilience.yml", jobName: "k6-soak", stepName: "Build CLI bundle" },
+  { file: "nightly-llm-security.yml", jobName: "promptfoo-guard", stepName: "Build CLI bundle" },
+  { file: "nightly-llm-security.yml", jobName: "garak", stepName: "Build CLI bundle" },
+];
+
+for (const { file, jobName, stepName } of TARGETS) {
+  test(`${file} :: ${jobName} '${stepName}' step sets OMNIROUTE_BUILD_BACKEND_ONLY=1 (skips dashboard UI build the API-only smoke job never exercises)`, () => {
+    const doc = loadWorkflow(file);
+    const job = doc.jobs[jobName];
+    assert.ok(job, `${file} must have a '${jobName}' job`);
+    const step = job.steps.find((s) => s.name === stepName);
+    assert.ok(step, `${file}'s '${jobName}' job must have a '${stepName}' step`);
+    assert.equal(
+      isBackendOnly(step),
+      true,
+      `${file}'s '${jobName}' -> '${stepName}' step must set OMNIROUTE_BUILD_BACKEND_ONLY=1 or OMNIROUTE_BUILD_PROFILE=backend`
+    );
+  });
+}
+
+test("npm-publish.yml 'Build CLI bundle (standalone app)' step must NOT be backend-only (it legitimately ships the full dashboard UI)", () => {
+  const doc = loadWorkflow("npm-publish.yml");
+  const publishJob = Object.values(doc.jobs).find((job) =>
+    job.steps.some((s) => s.name === "Build CLI bundle (standalone app)")
+  );
+  assert.ok(publishJob, "npm-publish.yml must have a job with a 'Build CLI bundle (standalone app)' step");
+  const step = publishJob!.steps.find((s) => s.name === "Build CLI bundle (standalone app)")!;
+  assert.equal(
+    isBackendOnly(step),
+    false,
+    "npm-publish.yml's build step must ship the full dashboard UI, not the backend-only stub"
+  );
+});