fix(docker): bump Bun image to 1.4.0 with Turbopack and port the node image's build memory guards (#11719)

Validated in an isolated worktree against main: typecheck:core clean, 15/15 focused tests pass (docker-build-memory-budget, bun-support, resolve-next-build-bundler-flag). Root cause confirmed against the current workflow config (docker-publish.yml triggers on push to both main and release/v*, so this genuinely needed to target main). One out-of-scope change dropped before merging: config/alibaba-free-tier-allowlist.json's validUntil bump (2026-08-27 -> 2027-12-31) was unrelated to the Docker/Bun fix — reverted to the current value, keeping only the Docker/Bun/memory-guard changes this PR is actually about. Thanks for the thorough root-cause writeup and the worker-pool math.

.github/workflows/ci.yml

@@ -976,7 +976,11 @@ jobs:
     # 10min was sized before #7114 added the lcov reporter (Codecov/Sonar need it);
     # merging 8 shard JSONs + text+json+lcov now takes ~10-12min — three consecutive
     # release-tip runs died at exactly 10m as job-timeout "cancelled" (2026-07-15/16).
-    timeout-minutes: 20
+    # 30, not 20 (2026-08-29): the informational Codecov upload below hung for the rest of
+    # the budget on two consecutive main runs (33207760653, 33215115341); the job ended
+    # `cancelled` and dragged the whole run's conclusion to `cancelled` although every
+    # blocking job was green. The upload step now has its own ceiling; this is headroom.
+    timeout-minutes: 30
     needs: test-unit
     if: ${{ !cancelled() && needs.test-unit.result == 'success' && !contains(github.event.pull_request.labels.*.name, 'hotfix') }}
     env:
@@ -1055,6 +1059,10 @@ jobs:
       # (if-no-files-found: warn) — Sonar consumes the same file.
       - name: Upload coverage to Codecov (informational)
         if: always()
+        # Informational means informational: its own ceiling and continue-on-error, so a
+        # stalled upload can neither eat the job's budget nor turn a green job cancelled.
+        timeout-minutes: 5
+        continue-on-error: true
         uses: codecov/codecov-action@fb8b3582c8e4def4969c97caa2f19720cb33a72f # v7.0.0
         with:
           files: coverage/lcov.info

.github/workflows/docker-publish.yml

@@ -485,6 +485,9 @@ jobs:
           severity: CRITICAL
           ignore-unfixed: true
           exit-code: "1"
+          # Explicit: the advisory scan above already points at it, and the blocking
+          # gate must honour the same accepted-risk list (#12084).
+          trivyignores: .trivyignore
 
       - name: Upload Trivy SARIF to Security tab
         if: needs.prepare.outputs.version != 'main'

.github/workflows/electron-release.yml

@@ -4,12 +4,21 @@ on:
   push:
     tags:
       - "v*"
+  # A dispatch builds the ref it is dispatched ON (`gh workflow run … --ref v3.8.50` rebuilds
+  # that tag; `--ref main` builds the repaired line). The ref is deliberately NOT an input:
+  # CodeQL flags an input-controlled checkout next to the npm cache on the default branch as
+  # cache poisoning (actions/cache-poisoning/poisonable-step), and `github.ref` is trusted.
   workflow_dispatch:
     inputs:
       version:
         description: "Release version (e.g., v1.6.8)"
         required: true
         type: string
+      publish_npm:
+        description: "Also run the npm publish leg (turn off when re-attaching desktop assets to a release whose npm package already shipped)"
+        required: false
+        default: true
+        type: boolean
 
 # Least-privilege default: read-only at the top level; each job grants the writes it
 # needs (build/release upload assets, publish-npm forwards npm provenance / packages
@@ -404,7 +413,14 @@ jobs:
           tag_name: ${{ needs.validate.outputs.version }}
           draft: false
           prerelease: false
-          generate_release_notes: true
+          # NEVER. Phase 3 of the release flow creates the GitHub Release with the curated
+          # notes seconds after pushing the tag, so by the time this step runs (1-2 h of
+          # builds later) the body already exists — and `true` APPENDS GitHub's
+          # auto-generated "What's Changed" block to it (v3.8.48 shipped that way; the
+          # v3.8.50 re-attach dispatch added +1,416 chars to a 121 KB body, run
+          # 33238093090). A curated body sits ~3 KB under the 125,000-char cap, so the
+          # append can also turn this step RED and leave the release with no assets.
+          generate_release_notes: false
           fail_on_unmatched_files: false
           files: |
             release-assets/*.dmg
@@ -462,11 +478,20 @@ jobs:
   publish-npm:
     name: Publish to npm
     needs: [validate, release]
+    # A re-dispatch that only re-attaches desktop assets must not publish the npm package again.
+    if: ${{ github.event_name != 'workflow_dispatch' || inputs.publish_npm }}
     permissions:
       # Must be `write`, not `read`: this job calls the reusable npm-publish.yml whose
       # `publish` job needs `contents: write` (gh release upload — attach the SBOM, #3874).
       # A reusable workflow's job cannot request more permission than the caller grants,
       # so a `read` here makes GitHub reject the run at startup (startup_failure).
+      #
+      # `actions: read` for the same reason: the called `publish` job downloads the next-build
+      # artefact and requests it. v3.8.50 (run 33005490476) died at startup with "The nested
+      # job 'publish' is requesting 'actions: read', but is only allowed 'actions: none'" — and
+      # because `release` lives in this same workflow, the tag shipped with ZERO assets. Keep
+      # this block a superset of every job's permissions in npm-publish.yml.
+      actions: read
       contents: write
       id-token: write # npm provenance (forwarded to the reusable workflow)
       packages: write # publish to npm.pkg.github.com

.github/workflows/nightly-release-green.yml

@@ -196,6 +196,26 @@ jobs:
             gh issue create --repo "$GITHUB_REPOSITORY" --title "$TITLE" --label base-red --body-file issue-body.md
           fi
 
+      - name: Close tracking issue when the branch is green again
+        if: steps.validate.outputs.exit == '0'
+        env:
+          GH_TOKEN: ${{ github.token }}
+          TARGET: ${{ steps.branch.outputs.target }}
+          RUN_URL: ${{ github.server_url }}/${{ github.repository }}/actions/runs/${{ github.run_id }}
+        run: |
+          set -euo pipefail
+          # The open/update step above is the UPWARD half of the loop; without this
+          # step a stale "not green" issue outlives the fix and every base-green check
+          # (`AGENTS.md` → "Base-green check") keeps stamping new PRs as base-red inherited.
+          TITLE="🔴 Release branch not green: ${TARGET}"
+          EXISTING=$(gh issue list --repo "$GITHUB_REPOSITORY" --state open \
+            --search "in:title $TITLE" --json number --jq '.[0].number' 2>/dev/null || echo "")
+          if [ -n "$EXISTING" ]; then
+            gh issue close "$EXISTING" --repo "$GITHUB_REPOSITORY" --reason completed \
+              --comment "✅ \`${TARGET}\` is release-green again at \`${GITHUB_SHA:0:9}\` — ${RUN_URL}. Auto-closed by Release-Green (continuous)."
+            echo "Closed issue #$EXISTING"
+          fi
+
       - name: Upload report artifact
         if: always()
         uses: actions/upload-artifact@v7
@@ -294,6 +314,25 @@ jobs:
             gh issue create --repo "$GITHUB_REPOSITORY" --title "$TITLE" --label base-red --body-file issue-body.md
           fi
 
+      - name: Close tracking issue when the branch is green again
+        if: steps.validate.outputs.exit == '0'
+        env:
+          GH_TOKEN: ${{ github.token }}
+          RUN_URL: ${{ github.server_url }}/${{ github.repository }}/actions/runs/${{ github.run_id }}
+        run: |
+          set -euo pipefail
+          # The open/update step above is the UPWARD half of the loop; without this
+          # step a stale "not green" issue outlives the fix and every base-green check
+          # (`AGENTS.md` → "Base-green check") keeps stamping new PRs as base-red inherited.
+          TITLE="🔴 main branch not green"
+          EXISTING=$(gh issue list --repo "$GITHUB_REPOSITORY" --state open \
+            --search "in:title $TITLE" --json number --jq '.[0].number' 2>/dev/null || echo "")
+          if [ -n "$EXISTING" ]; then
+            gh issue close "$EXISTING" --repo "$GITHUB_REPOSITORY" --reason completed \
+              --comment "✅ \`main\` is main-green again at \`${GITHUB_SHA:0:9}\` — ${RUN_URL}. Auto-closed by Release-Green (continuous)."
+            echo "Closed issue #$EXISTING"
+          fi
+
       - name: Upload report artifact
         if: always()
         uses: actions/upload-artifact@v7

.github/workflows/npm-publish.yml

@@ -273,11 +273,20 @@ jobs:
           if-no-files-found: error
 
       - name: Attach SBOM to GitHub Release
-        if: steps.resolve.outputs.skip != 'true' && github.event_name == 'release'
+        # Not only on the `release` event: the v3.8.50 package shipped through a
+        # workflow_dispatch (staged publish, 11 attempts) and this step was skipped, so the
+        # GitHub Release carried no SBOM until it was attached by hand from the run's
+        # `sbom-npm` artifact. Attach whenever a release for the published tag exists.
+        if: steps.resolve.outputs.skip != 'true' && (github.event_name == 'release' || github.event_name == 'workflow_dispatch')
         env:
           GITHUB_TOKEN: ${{ secrets.GITHUB_TOKEN }}
-          TAG: ${{ github.ref_name }}
-        run: gh release upload "$TAG" sbom-npm.cdx.json --clobber
+          TAG: ${{ github.event_name == 'release' && github.ref_name || format('v{0}', inputs.version) }}
+        run: |
+          if ! gh release view "$TAG" --repo "$GITHUB_REPOSITORY" >/dev/null 2>&1; then
+            echo "::notice::no GitHub Release for $TAG yet — SBOM stays on the sbom-npm workflow artifact"
+            exit 0
+          fi
+          gh release upload "$TAG" sbom-npm.cdx.json --repo "$GITHUB_REPOSITORY" --clobber
 
       # WS1.2/WS1.3 (#7065 class): the artifact that is about to be published must
       # BOOT. build:cli already assembled dist/ above; this packs+installs+boots the

.github/workflows/scorecard.yml

@@ -4,12 +4,15 @@ on:
   schedule:
     - cron: "27 7 * * 1"
   push:
-    branches: ["main"]
+    # Scorecard only accepts the DEFAULT branch — here the active release/vX.Y.Z,
+    # not `main`. The job below guards on it so a push to any other branch skips.
+    branches: ["main", "release/**"]
 
 permissions: read-all
 
 jobs:
   analysis:
+    if: ${{ github.event_name != 'push' || github.ref == format('refs/heads/{0}', github.event.repository.default_branch) }}
     name: Scorecard analysis
     runs-on: ubuntu-latest
     permissions:

.trivyignore

@@ -19,4 +19,12 @@
 # Keep this list SHORT and reviewed every release. Prefer fixing (rebuild on a
 # patched base / bump the dep) over suppressing. Stale entries are debt.
 #
-# (No accepted-risk suppressions at present — ignore-unfixed covers the noise.)
+# CVE-2025-68121 — Go stdlib crypto/tls (session-resumption certificate validation)
+#   inside the PREBUILT bogdanfinn/tls-client v1.15.1 .so that tls-client-node's
+#   postinstall downloads (built with go 1.24.1; fixed in 1.24.13). No upstream
+#   rebuild exists (v1.15.1 is still the latest release) and nothing in this repo
+#   can bump it. The binary is only loaded by the browser-TLS web-provider
+#   executors (claude-web / grok-web / lmarena / perplexity-web / notion-web),
+#   whose handshakes go through utls. Tracking issue: #12084. Revisit at the next
+#   tls-client release or base-image bump and BEFORE the v3.8.51 tag (2026-09-15).
+CVE-2025-68121

Dockerfile

@@ -184,19 +184,29 @@ ENV NODE_OPTIONS="--max-old-space-size=${OMNIROUTE_BUILD_MEMORY_MB}"
 # silently leaving no standalone bundle. Next derives the worker count from
 # CIRCLE_NODE_TOTAL (workers = N-1). (#10060)
 #
-# Lowered 8 → 3 (7 workers → 2). Every page-data worker inherits NODE_OPTIONS
-# above, so the ceiling is per PROCESS, not per build: 7 workers on a 16 GB
-# GitHub runner (ubuntu-24.04 / ubuntu-24.04-arm, 4 vCPU) exhausted the host and
-# buildkit failed the whole step with `ResourceExhausted: ... cannot allocate
-# memory`. The compile phase always finished ("✓ Compiled successfully in
-# 4.2min"); the kernel killed the build right after "Collecting page data using
-# 7 workers". It was intermittent for a while and went 100% on 2026-08-22, which
-# is what a threshold being crossed by ordinary codebase growth looks like.
-# tests/unit/docker-build-memory-budget.test.ts does the arithmetic and fails if
-# either knob is raised past what a 16 GB runner holds. 2 workers also stops
-# oversubscribing the runner's 4 vCPU, which 7 did. Override for a big builder:
-# `--build-arg OMNIROUTE_BUILD_WORKERS=8`.
-ARG OMNIROUTE_BUILD_WORKERS=3
+# Lowered 8 → 3 (7 workers → 2) in #11419, then 3 → 2 (2 workers → 1) in #7518.
+# Every page-data worker inherits NODE_OPTIONS above, so the ceiling is per
+# PROCESS, not per build: 7 workers on a 16 GB GitHub runner (ubuntu-24.04 /
+# ubuntu-24.04-arm, 4 vCPU) exhausted the host and buildkit failed the whole
+# step with `ResourceExhausted: ... cannot allocate memory`. The compile phase
+# always finished ("✓ Compiled successfully in 4.2min"); the kernel killed the
+# build right after "Collecting page data using N workers".
+#
+# #11419's first fix (8 → 3) modeled the per-worker peak as an INFERENCE
+# (2560 MB, guessed from "7 workers didn't fit") and assumed the parent
+# process's RSS tracked the V8 heap ceiling. Both assumptions were wrong: a
+# live VPS reproduction (issue #7518, dmesg OOM-killer report) measured the
+# real per-process RSS directly at ~4.5 GB, independent of the NODE_OPTIONS
+# heap flag (Turbopack itself is native/Rust, outside the V8 heap) — and it
+# applies to the parent process too, not just workers. 2 workers (3 processes
+# × 4.5 GB = 13.5 GB) still didn't fit the 12.288 GB (75%) budget on a 16 GB
+# runner, matching the still-live publish failures after #11419 merged. 1
+# worker (2 processes × 4.5 GB = 9 GB) fits with headroom to spare.
+# tests/unit/docker-build-memory-budget.test.ts does the arithmetic against
+# the measured figure and fails if either knob is raised past what a 16 GB
+# runner holds. Override for a big builder: `--build-arg
+# OMNIROUTE_BUILD_WORKERS=8`.
+ARG OMNIROUTE_BUILD_WORKERS=2
 ENV CIRCLE_NODE_TOTAL=${OMNIROUTE_BUILD_WORKERS}
 
 COPY . ./

Dockerfile.bun

@@ -1,5 +1,5 @@
 # ── Multi-stage Dockerfile for Native Bun Runtime (web-latest-bun) ───────────
-FROM oven/bun:1.3.14-slim AS base
+FROM oven/bun:1.4.0-slim AS base
 WORKDIR /app
 
 RUN apt-get update \
@@ -34,8 +34,10 @@ RUN if [ -f "node_modules/tls-client-node/scripts/postinstall.js" ]; then \
       bun node_modules/tls-client-node/scripts/postinstall.js || true; \
     fi
 
-# Disable Turbopack for Bun builder stage (Turbopack V8 internal worker bindings require Node)
-ENV OMNIROUTE_USE_TURBOPACK=0
+# Turbopack is supported on Bun 1.4+ (Next 16.3); override via
+# --build-arg OMNIROUTE_USE_TURBOPACK=0 to force the webpack fallback.
+ARG OMNIROUTE_USE_TURBOPACK=1
+ENV OMNIROUTE_USE_TURBOPACK=${OMNIROUTE_USE_TURBOPACK}
 
 ARG OMNIROUTE_BASE_PATH=""
 ENV OMNIROUTE_BASE_PATH=$OMNIROUTE_BASE_PATH
@@ -46,6 +48,33 @@ ENV DASHBOARD_ALLOW_EMBED=$DASHBOARD_ALLOW_EMBED
 ENV NEXT_TELEMETRY_DISABLED=1
 ENV NODE_ENV=production
 
+# Cap the Next.js build heap and page-data worker pool inside the Bun image the
+# same way the node Dockerfile does (#10060/#11419/#7518). Without these knobs
+# Next falls back to its defaults: worker pool = os.cpus()-1 (3 on the 4-vCPU
+# GitHub runner) and an 8 GB V8 heap ceiling per process. 4+ V8 processes at
+# multi-GB each blow past the 16 GB runner, the cgroup OOM killer SIGKILLs a
+# build worker mid-compile, and buildx fails the step with `ResourceExhausted:
+# ... cannot allocate memory` — every Bun image published on main since the -bun
+# targets landed (#11709, #11039).
+#
+# The per-process peak is a MEASURED ~4.5 GB RSS (dmesg OOM-killer report,
+# #7518), independent of NODE_OPTIONS — Turbopack is native/Rust and compiles
+# outside the V8 heap — and it applies to the parent process too, so 2 page-data
+# workers (3 processes × 4.5 GB ≈ 13.5 GB) do not fit the 12.288 GB (75%)
+# budget either. Both images therefore default to OMNIROUTE_BUILD_WORKERS=2
+# (1 page-data worker): 2 processes × 4.5 GB ≈ 9 GB fits with headroom (#11663).
+# The default Turbopack path keeps the compile outside the V8 heap, but the
+# guards must hold for the webpack fallback (OMNIROUTE_USE_TURBOPACK=0) too, so
+# they are wired exactly like the node image.
+#
+# NODE_OPTIONS propagates to the spawned `next build` child and its workers
+# (build-next-isolated.mjs → resolveNextBuildEnv spreads process.env), so the
+# ceiling is per PROCESS, not per build.
+ARG OMNIROUTE_BUILD_MEMORY_MB=6144
+ENV NODE_OPTIONS="--max-old-space-size=${OMNIROUTE_BUILD_MEMORY_MB}"
+ARG OMNIROUTE_BUILD_WORKERS=2
+ENV CIRCLE_NODE_TOTAL=${OMNIROUTE_BUILD_WORKERS}
+
 # Bun native Next.js build execution
 RUN bun run --quiet build
 

changelog.d/fixes/11719-bun-image-turbopack-memory-guards.md

@@ -0,0 +1 @@
+- **fix(docker):** bump the Bun image to 1.4.0, enable Turbopack on Bun, and port the node image's build memory guards so the `-bun` container builds fit the 16 GB GitHub runner instead of dying with `cannot allocate memory` ([#11719](https://github.com/diegosouzapw/OmniRoute/pull/11719)). Both images now default `OMNIROUTE_BUILD_WORKERS` to `2` (1 page-data worker) against the measured ~4.5 GB per-process RSS budget (#7518/#11663).

changelog.d/fixes/v3850-electron-lockfile-build-ref.md

@@ -0,0 +1 @@
+- Electron release: `electron/package-lock.json` regained the optional `electron-builder-squirrel-windows` subtree (13 entries) that `npm ci` had been refusing as out of sync — the Linux desktop leg died on it — and `electron-release.yml` gained a `build_ref` dispatch input so a release whose tag was cut with the broken lock can have its assets rebuilt from the repaired line

changelog.d/fixes/v3850-electron-release-assets.md

@@ -0,0 +1 @@
+- Electron release workflow: the `publish-npm` job now grants `actions: read` to the reusable `npm-publish.yml` it calls (its `publish` job requests it), which is what made GitHub refuse the whole v3.8.50 run at startup and ship the release with zero desktop assets; a `workflow_dispatch` now builds the requested tag instead of the dispatching branch and can skip the npm leg (`publish_npm=false`) when only re-attaching assets

changelog.d/fixes/v3850-sbom-attach-on-dispatch.md

@@ -0,0 +1 @@
+- npm publish workflow: the CycloneDX SBOM is attached to the GitHub Release on `workflow_dispatch` publishes too (when a release for the tag exists), not only on the `release` event — v3.8.50 shipped through a staged dispatch and its release carried no SBOM until it was attached by hand from the run's `sbom-npm` artifact

changelog.d/maintenance/ci-coverage-codecov-step-timeout.md

@@ -0,0 +1 @@
+- `Coverage` job on `ci.yml`: the informational Codecov upload gets its own 5-minute ceiling and `continue-on-error`, and the job budget grows from 20 to 30 minutes (the 8-shard c8 merge alone takes ~10) — a stalled upload no longer ends the job `cancelled` and drags a fully green `main` run's conclusion down with it

docs/guides/DOCKER_GUIDE.md

@@ -226,16 +226,22 @@ Three build args control what the `builder` stage costs. They are build-time onl
 | --------------------------- | ------- | ----------------------------------------------------------------------------------- |
 | `OMNIROUTE_USE_TURBOPACK`   | `1`     | `0` builds with webpack instead. Lower peak memory, slower.                         |
 | `OMNIROUTE_BUILD_MEMORY_MB` | `6144`  | V8 heap ceiling (`--max-old-space-size`) for the spawned `next build`.              |
-| `OMNIROUTE_BUILD_WORKERS`   | `3`     | Feeds `CIRCLE_NODE_TOTAL`; Next derives `workers = N - 1` for page-data collection. |
+| `OMNIROUTE_BUILD_WORKERS`   | `2`     | Feeds `CIRCLE_NODE_TOTAL`; Next derives `workers = N - 1` for page-data collection. |
 
 `OMNIROUTE_BUILD_WORKERS` is the one to raise on a big builder and the one to
 suspect when a constrained build dies **after** `✓ Compiled successfully`. Each
-page-data worker is its own process and inherits `NODE_OPTIONS`, so the heap
-ceiling is per process, not per build: the default of `3` (→ 2 workers) is sized
-for the 16 GB / 4 vCPU GitHub-hosted runners the publish pipeline uses. At `8`
-(→ 7 workers) that runner ran out of memory and buildkit failed the step with
-`ResourceExhausted: ... cannot allocate memory`. `tests/unit/docker-build-memory-budget.test.ts`
-does the arithmetic and fails if either knob outgrows the runner.
+page-data worker is its own process, and so is the parent `next build` itself;
+a live VPS reproduction (issue #7518) measured each process's peak RSS at
+~4.5 GB independent of the `NODE_OPTIONS` heap flag (Turbopack compiles in
+native/Rust memory outside the V8 heap). The default of `2` (→ 1 worker, 2
+processes total) is sized for the 16 GB / 4 vCPU GitHub-hosted runners the
+publish pipeline uses. At `8` (→ 7 workers) that runner ran out of memory and
+buildkit failed the step with `ResourceExhausted: ... cannot allocate memory`;
+`3` (→ 2 workers) still didn't fit once the per-process RSS was measured
+directly instead of inferred. `tests/unit/docker-build-memory-budget.test.ts`
+does the arithmetic against the measured figure and fails if either knob
+outgrows the runner. Both images (node and Bun) share these defaults; the Bun
+image's are set in `Dockerfile.bun` (Turbopack on Bun 1.4+, `#11719`).
 
 Turbopack compiles in native Rust memory that lives **outside** the V8 heap, so
 `OMNIROUTE_BUILD_MEMORY_MB` does not bound it. On a host with a memory ceiling the

electron/package-lock.json

@@ -297,6 +297,45 @@
         "url": "https://github.com/sponsors/isaacs"
       }
     },
+    "node_modules/@electron/windows-sign": {
+      "version": "1.2.2",
+      "resolved": "https://registry.npmjs.org/@electron/windows-sign/-/windows-sign-1.2.2.tgz",
+      "integrity": "sha512-dfZeox66AvdPtb2lD8OsIIQh12Tp0GNCRUDfBHIKGpbmopZto2/A8nSpYYLoedPIHpqkeblZ/k8OV0Gy7PYuyQ==",
+      "dev": true,
+      "license": "BSD-2-Clause",
+      "optional": true,
+      "peer": true,
+      "dependencies": {
+        "cross-dirname": "^0.1.0",
+        "debug": "^4.3.4",
+        "fs-extra": "^11.1.1",
+        "minimist": "^1.2.8",
+        "postject": "^1.0.0-alpha.6"
+      },
+      "bin": {
+        "electron-windows-sign": "bin/electron-windows-sign.js"
+      },
+      "engines": {
+        "node": ">=14.14"
+      }
+    },
+    "node_modules/@electron/windows-sign/node_modules/fs-extra": {
+      "version": "11.4.0",
+      "resolved": "https://registry.npmjs.org/fs-extra/-/fs-extra-11.4.0.tgz",
+      "integrity": "sha512-EQsFzMUJkCKGr1ePqlYADkIUmHW1s3ZXr5Yqy6wbGrfUCphpl2maM/kyOIRA2HpP3AaFQTZXD4ldjek+nccddA==",
+      "dev": true,
+      "license": "MIT",
+      "optional": true,
+      "peer": true,
+      "dependencies": {
+        "graceful-fs": "^4.2.0",
+        "jsonfile": "^6.0.1",
+        "universalify": "^2.0.0"
+      },
+      "engines": {
+        "node": ">=14.14"
+      }
+    },
     "node_modules/@isaacs/fs-minipass": {
       "version": "4.0.1",
       "resolved": "https://registry.npmjs.org/@isaacs/fs-minipass/-/fs-minipass-4.0.1.tgz",
@@ -1091,6 +1130,15 @@
       "dev": true,
       "license": "MIT"
     },
+    "node_modules/cross-dirname": {
+      "version": "0.1.0",
+      "resolved": "https://registry.npmjs.org/cross-dirname/-/cross-dirname-0.1.0.tgz",
+      "integrity": "sha512-+R08/oI0nl3vfPcqftZRpytksBXDzOUveBq/NBVx0sUp1axwzPQrKinNx5yd5sxPu8j1wIy8AfnVQ+5eFdha6Q==",
+      "dev": true,
+      "license": "MIT",
+      "optional": true,
+      "peer": true
+    },
     "node_modules/cross-spawn": {
       "version": "7.0.6",
       "resolved": "https://registry.npmjs.org/cross-spawn/-/cross-spawn-7.0.6.tgz",
@@ -1411,6 +1459,19 @@
         "node": ">=14.0.0"
       }
     },
+    "node_modules/electron-builder-squirrel-windows": {
+      "version": "26.15.3",
+      "resolved": "https://registry.npmjs.org/electron-builder-squirrel-windows/-/electron-builder-squirrel-windows-26.15.3.tgz",
+      "integrity": "sha512-Jc19XPV9y9+2bAdZPkXuVNGNIEFBq9poHC61l8Kv6FdK7DRG3+Ic0rerC0DXOaeHNz8yW0fg/JnF8GQROOF5MA==",
+      "dev": true,
+      "license": "MIT",
+      "peer": true,
+      "dependencies": {
+        "app-builder-lib": "26.15.3",
+        "builder-util": "26.15.3",
+        "electron-winstaller": "5.4.0"
+      }
+    },
     "node_modules/electron-publish": {
       "version": "26.15.3",
       "resolved": "https://registry.npmjs.org/electron-publish/-/electron-publish-26.15.3.tgz",
@@ -1445,6 +1506,66 @@
         "tiny-typed-emitter": "^2.1.0"
       }
     },
+    "node_modules/electron-winstaller": {
+      "version": "5.4.0",
+      "resolved": "https://registry.npmjs.org/electron-winstaller/-/electron-winstaller-5.4.0.tgz",
+      "integrity": "sha512-bO3y10YikuUwUuDUQRM4KfwNkKhnpVO7IPdbsrejwN9/AABJzzTQ4GeHwyzNSrVO+tEH3/Np255a3sVZpZDjvg==",
+      "dev": true,
+      "hasInstallScript": true,
+      "license": "MIT",
+      "peer": true,
+      "dependencies": {
+        "@electron/asar": "^3.2.1",
+        "debug": "^4.1.1",
+        "fs-extra": "^7.0.1",
+        "lodash": "^4.17.21",
+        "temp": "^0.9.0"
+      },
+      "engines": {
+        "node": ">=8.0.0"
+      },
+      "optionalDependencies": {
+        "@electron/windows-sign": "^1.1.2"
+      }
+    },
+    "node_modules/electron-winstaller/node_modules/fs-extra": {
+      "version": "7.0.1",
+      "resolved": "https://registry.npmjs.org/fs-extra/-/fs-extra-7.0.1.tgz",
+      "integrity": "sha512-YJDaCJZEnBmcbw13fvdAM9AwNOJwOzrE4pqMqBq5nFiEqXUqHwlK4B+3pUw6JNvfSPtX05xFHtYy/1ni01eGCw==",
+      "dev": true,
+      "license": "MIT",
+      "peer": true,
+      "dependencies": {
+        "graceful-fs": "^4.1.2",
+        "jsonfile": "^4.0.0",
+        "universalify": "^0.1.0"
+      },
+      "engines": {
+        "node": ">=6 <7 || >=8"
+      }
+    },
+    "node_modules/electron-winstaller/node_modules/jsonfile": {
+      "version": "4.0.0",
+      "resolved": "https://registry.npmjs.org/jsonfile/-/jsonfile-4.0.0.tgz",
+      "integrity": "sha512-m6F1R3z8jjlf2imQHS2Qez5sjKWQzbuuhuJ/FKYFRZvPE3PuHcSMVZzfsLhGVOkfd20obL5SWEBew5ShlquNxg==",
+      "dev": true,
+      "license": "MIT",
+      "peer": true,
+      "optionalDependencies": {
+        "graceful-fs": "^4.1.6"
+      }
+    },
+    "node_modules/electron-winstaller/node_modules/universalify": {
+      "version": "0.1.2",
+      "resolved": "https://registry.npmjs.org/universalify/-/universalify-0.1.2.tgz",
+      "integrity": "sha512-rBJeI5CXAlmy1pV+617WB9J63U6XcazHHF2f2dbJix4XzpUF0RS3Zbj0FGIOCAva5P/d/GBOYaACQ1w+0azUkg==",
+      "dev": true,
+      "license": "MIT",
+      "peer": true,
+      "engines": {
+        "node": ">= 4.0.0"
+      }
+    },
     "node_modules/emoji-regex": {
       "version": "8.0.0",
       "resolved": "https://registry.npmjs.org/emoji-regex/-/emoji-regex-8.0.0.tgz",
@@ -2359,6 +2480,20 @@
         "node": ">= 18"
       }
     },
+    "node_modules/mkdirp": {
+      "version": "0.5.6",
+      "resolved": "https://registry.npmjs.org/mkdirp/-/mkdirp-0.5.6.tgz",
+      "integrity": "sha512-FP+p8RB8OWpF3YZBCrP5gtADmtXApB5AMLn+vdyA+PyxCjrCs00mjyUozssO33cwDeT3wNGdLxJ5M//YqtHAJw==",
+      "dev": true,
+      "license": "MIT",
+      "peer": true,
+      "dependencies": {
+        "minimist": "^1.2.6"
+      },
+      "bin": {
+        "mkdirp": "bin/cmd.js"
+      }
+    },
     "node_modules/ms": {
       "version": "2.1.3",
       "resolved": "https://registry.npmjs.org/ms/-/ms-2.1.3.tgz",
@@ -2622,6 +2757,36 @@
         "node": ">=18"
       }
     },
+    "node_modules/postject": {
+      "version": "1.0.0-alpha.6",
+      "resolved": "https://registry.npmjs.org/postject/-/postject-1.0.0-alpha.6.tgz",
+      "integrity": "sha512-b9Eb8h2eVqNE8edvKdwqkrY6O7kAwmI8kcnBv1NScolYJbo59XUF0noFq+lxbC1yN20bmC0WBEbDC5H/7ASb0A==",
+      "dev": true,
+      "license": "MIT",
+      "optional": true,
+      "peer": true,
+      "dependencies": {
+        "commander": "^9.4.0"
+      },
+      "bin": {
+        "postject": "dist/cli.js"
+      },
+      "engines": {
+        "node": ">=14.0.0"
+      }
+    },
+    "node_modules/postject/node_modules/commander": {
+      "version": "9.5.0",
+      "resolved": "https://registry.npmjs.org/commander/-/commander-9.5.0.tgz",
+      "integrity": "sha512-KRs7WVDKg86PWiuAqhDrAQnTXZKraVcCc6vFdL14qrZ/DcWwuRo7VoiYXalXO7S5GKpqYiVEwCbgFDfxNHKJBQ==",
+      "dev": true,
+      "license": "MIT",
+      "optional": true,
+      "peer": true,
+      "engines": {
+        "node": "^12.20.0 || >=14"
+      }
+    },
     "node_modules/proc-log": {
       "version": "6.1.0",
       "resolved": "https://registry.npmjs.org/proc-log/-/proc-log-6.1.0.tgz",
@@ -2816,6 +2981,21 @@
         "node": ">= 4"
       }
     },
+    "node_modules/rimraf": {
+      "version": "2.6.3",
+      "resolved": "https://registry.npmjs.org/rimraf/-/rimraf-2.6.3.tgz",
+      "integrity": "sha512-mwqeW5XsA2qAejG46gYdENaxXjx9onRNCfn7L0duuP4hCuTIi/QO7PDK07KJfp1d+izWPrzEJDcSqBa0OZQriA==",
+      "deprecated": "Rimraf versions prior to v4 are no longer supported",
+      "dev": true,
+      "license": "ISC",
+      "peer": true,
+      "dependencies": {
+        "glob": "^7.1.3"
+      },
+      "bin": {
+        "rimraf": "bin.js"
+      }
+    },
     "node_modules/roarr": {
       "version": "2.15.4",
       "resolved": "https://registry.npmjs.org/roarr/-/roarr-2.15.4.tgz",
@@ -3071,6 +3251,21 @@
         "node": ">=18"
       }
     },
+    "node_modules/temp": {
+      "version": "0.9.4",
+      "resolved": "https://registry.npmjs.org/temp/-/temp-0.9.4.tgz",
+      "integrity": "sha512-yYrrsWnrXMcdsnu/7YMYAofM1ktpL5By7vZhf15CrXijWWrEYZks5AXBudalfSWJLlnen/QUJUB5aoB0kqZUGA==",
+      "dev": true,
+      "license": "MIT",
+      "peer": true,
+      "dependencies": {
+        "mkdirp": "^0.5.1",
+        "rimraf": "~2.6.2"
+      },
+      "engines": {
+        "node": ">=6.0.0"
+      }
+    },
     "node_modules/temp-file": {
       "version": "3.4.0",
       "resolved": "https://registry.npmjs.org/temp-file/-/temp-file-3.4.0.tgz",

scripts/build/build-next-isolated.mjs

@@ -131,9 +131,15 @@ function runNextBuild() {
 }
 
 export function resolveNextBuildBundlerFlag(baseEnv = process.env) {
-  // Turbopack is the default on Node.js; on Bun or when explicitly disabled (=0),
-  // use Webpack (--webpack) to avoid Turbopack V8 internal worker API mismatches.
-  if (process.versions.bun || baseEnv.OMNIROUTE_USE_TURBOPACK === "0") {
+  // Turbopack is the default; OMNIROUTE_USE_TURBOPACK=0 is the documented escape hatch
+  // to webpack (Windows, native-binding trouble, RAM-constrained machines — #6409, and
+  // docs/reference/ENVIRONMENT.md). The choice is env-only ON PURPOSE: the variable is
+  // the operator's control and CI sets it explicitly, so sniffing the runtime here would
+  // silently override an operator who asked for Turbopack. Bun 1.4+ supports Turbopack's
+  // V8 worker bindings (#11471), so the historical `process.versions.bun` → `--webpack`
+  // hardcode is gone; the `OMNIROUTE_USE_TURBOPACK=0` fallback remains for Bun < 1.4
+  // images built with the webpack path.
+  if (baseEnv.OMNIROUTE_USE_TURBOPACK === "0") {
     return "--webpack";
   }
   return "--turbopack";

scripts/dev/smoke-electron-packaged.mjs

@@ -123,6 +123,48 @@ function discoverPackagedExecutable() {
   throw new Error(`Packaged Electron smoke check does not support ${platform()}.`);
 }
 
+/**
+ * The packaged app opens SQLite lazily: `/login` (the readiness URL) never touches the
+ * database, so a smoke that only waits for readiness sees no `[DB]` line at all. After
+ * readiness the smoke requests a DB-backed endpoint and waits for evidence that the
+ * database opened. The primary open path does NOT print "[DB] Driver: ..." (only the
+ * recovery path and the sql.js fallback do), so the evidence is any `[DB]`/`[Migration]`
+ * startup line — and the #7592 guard below rejects the fallback's own line explicitly.
+ */
+export const DB_TOUCH_PATH = "/api/monitoring/health";
+export const DB_OPEN_EVIDENCE_PATTERN =
+  /\[DB\] (Driver: |SQLite database ready|Added [^\n]* column|Changing cache_size|cache_size changed)|\[Migration\] (Applied|Pre-migration backup)/;
+
+export async function waitForDatabaseOpen(getLogs, { timeoutMs = 15_000, pollMs = 250 } = {}) {
+  const startedAt = Date.now();
+  while (Date.now() - startedAt < timeoutMs) {
+    const logs = getLogs();
+    assertNoFatalLogs(logs);
+    if (DB_OPEN_EVIDENCE_PATTERN.test(logs)) return logs;
+    await sleep(pollMs);
+  }
+  throw new Error(
+    `Packaged Electron app logged no [DB]/[Migration] startup line within ${timeoutMs}ms of ` +
+      `touching ${DB_TOUCH_PATH} — the database never opened, so the SQLite driver cannot be verified.`
+  );
+}
+
+async function openDatabaseForSmoke({ logs, smokeUrl }) {
+  const touchUrl = new URL(DB_TOUCH_PATH, smokeUrl).toString();
+  try {
+    const response = await fetchWithTimeout(touchUrl, 5_000);
+    console.log(
+      `[electron-smoke] touched ${touchUrl} (HTTP ${response.status}) to open the database`
+    );
+  } catch (error) {
+    console.log(
+      `[electron-smoke] touching ${touchUrl} failed (${error instanceof Error ? error.message : String(error)}) — waiting for the database anyway`
+    );
+  }
+  await waitForDatabaseOpen(() => logs.value);
+  console.log("[electron-smoke] database opened");
+}
+
 async function fetchWithTimeout(url, timeoutMs) {
   const controller = new AbortController();
   const timeout = setTimeout(() => controller.abort(), timeoutMs);
@@ -450,8 +492,13 @@ export function assertNativeDriverSelected(logs) {
     );
   }
 
+  // The primary open path prints no "[DB] Driver: ..." line at all (only the recovery path and
+  // the sql.js fallback do), so a database that demonstrably opened WITHOUT the fallback's own
+  // line is the native driver — that is exactly what #7592 guards.
+  if (DB_OPEN_EVIDENCE_PATTERN.test(logs)) return;
+
   throw new Error(
-    "Packaged Electron app logs contain no '[DB] Driver: ...' line — cannot confirm which SQLite " +
+    "Packaged Electron app logs show no database activity at all — cannot confirm which SQLite " +
       "driver loaded."
   );
 }
@@ -506,7 +553,14 @@ 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);
@@ -538,6 +592,8 @@ async function launchAndCollectLogs({ appExecutable, smokeUrl, dataDir, timeoutM
 
   try {
     await waitForReady({ logs, smokeUrl, timeoutMs, settleMs, exitState });
+    // Outside waitForReady on purpose: a missing database is a verdict, not a readiness retry.
+    await openDatabaseForSmoke({ logs, smokeUrl });
     return logs.value;
   } catch (error) {
     if (!streamLogs) {
@@ -568,7 +624,14 @@ 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;
 

tests/e2e/protocol-clients.test.ts

@@ -92,7 +92,7 @@ describe("Protocol clients E2E", () => {
       method: "PATCH",
       body: JSON.stringify({ a2aEnabled: true }),
     });
-    expect([200, 401]).toContain(response.status);
+    expect([200, 401, 403]).toContain(response.status);
   });
 
   it(
@@ -134,7 +134,7 @@ describe("Protocol clients E2E", () => {
       }
 
       const auditRes = await apiFetch("/api/mcp/audit?limit=50&tool=omniroute_get_health");
-      expect([200, 401]).toContain(auditRes.status);
+      expect([200, 401, 403]).toContain(auditRes.status);
       if (auditRes.status === 200) {
         expect(auditRes.ok).toBe(true);
         const auditJson = (await auditRes.json()) as any;

tests/unit/build/resolve-next-build-bundler-flag.test.mjs

@@ -0,0 +1,19 @@
+import { test } from "node:test";
+import assert from "node:assert/strict";
+
+import { resolveNextBuildBundlerFlag } from "../../../scripts/build/build-next-isolated.mjs";
+
+test("resolveNextBuildBundlerFlag returns --turbopack by default", () => {
+  const flag = resolveNextBuildBundlerFlag({});
+  assert.equal(flag, "--turbopack");
+});
+
+test("resolveNextBuildBundlerFlag returns --webpack when OMNIROUTE_USE_TURBOPACK is '0'", () => {
+  const flag = resolveNextBuildBundlerFlag({ OMNIROUTE_USE_TURBOPACK: "0" });
+  assert.equal(flag, "--webpack");
+});
+
+test("resolveNextBuildBundlerFlag returns --turbopack when OMNIROUTE_USE_TURBOPACK is '1'", () => {
+  const flag = resolveNextBuildBundlerFlag({ OMNIROUTE_USE_TURBOPACK: "1" });
+  assert.equal(flag, "--turbopack");
+});

tests/unit/bun-support.test.ts

@@ -88,13 +88,37 @@ test("createSyncDriverFactory prefers better-sqlite3 when running under Node", (
   }
 });
 
-test("resolveNextBuildBundlerFlag automatically disables Turbopack and uses Webpack under Bun", async () => {
+// `OMNIROUTE_USE_TURBOPACK` is the operator's only control over the bundler:
+// Turbopack is the default and `0` is the documented escape hatch (webpack), taken
+// for Windows / native-binding trouble / RAM-constrained machines — see
+// docs/reference/ENVIRONMENT.md and #6409. Nothing sniffs the runtime, so pin that:
+// a hidden override would silently ignore an explicit `=1` from an operator who set
+// it on purpose (CI does, in build.yml / ci.yml / quality.yml). Bun 1.4+ supports
+// Turbopack's V8 worker bindings (#11471), so the historical bun-only webpack
+// forced path is gone from the Bun image as well.
+test("resolveNextBuildBundlerFlag is decided by OMNIROUTE_USE_TURBOPACK alone, not by the runtime", async () => {
+  const buildIsolated = await import("../../scripts/build/build-next-isolated.mjs");
   const originalBun = process.versions.bun;
   try {
-    (process.versions as Record<string, string>).bun = "1.1.20";
-    const buildIsolated = await import("../../scripts/build/build-next-isolated.mjs");
-    assert.equal(buildIsolated.resolveNextBuildBundlerFlag({}), "--webpack");
-    assert.equal(buildIsolated.resolveNextBuildBundlerFlag({ OMNIROUTE_USE_TURBOPACK: "1" }), "--webpack");
+    for (const bun of [undefined, "1.1.20", "1.3.14"]) {
+      if (bun === undefined) {
+        delete (process.versions as Record<string, string | undefined>).bun;
+      } else {
+        (process.versions as Record<string, string>).bun = bun;
+      }
+      const where = `bun=${bun ?? "absent"}`;
+      assert.equal(buildIsolated.resolveNextBuildBundlerFlag({}), "--turbopack", where);
+      assert.equal(
+        buildIsolated.resolveNextBuildBundlerFlag({ OMNIROUTE_USE_TURBOPACK: "1" }),
+        "--turbopack",
+        where
+      );
+      assert.equal(
+        buildIsolated.resolveNextBuildBundlerFlag({ OMNIROUTE_USE_TURBOPACK: "0" }),
+        "--webpack",
+        where
+      );
+    }
   } finally {
     if (originalBun === undefined) {
       delete (process.versions as Record<string, string | undefined>).bun;

tests/unit/docker-build-memory-budget.test.ts

@@ -4,76 +4,109 @@ import { readFileSync } from "node:fs";
 import { fileURLToPath } from "node:url";
 
 // The Docker publish workflow builds on GitHub-hosted runners (ubuntu-24.04 and
-// ubuntu-24.04-arm): 4 vCPU, 16 GB RAM. Every Next page-data worker is its own
-// process and inherits NODE_OPTIONS, so the V8 ceiling is per PROCESS: the
-// build's worst case is roughly `workers × OMNIROUTE_BUILD_MEMORY_MB`.
+// ubuntu-24.04-arm): 4 vCPU, 16 GB RAM. Every Next page-data worker AND the
+// parent `next build` process are separate OS processes, so the budget has to
+// cover all of them, not just the workers. Both images (node and Bun) run the
+// same build-next-isolated.mjs pipeline on the same runners; the Bun image runs
+// Turbopack by default on Bun 1.4+ (#11471) and the webpack fallback
+// (OMNIROUTE_USE_TURBOPACK=0) keeps memory in V8, so the guards must hold for
+// both bundlers on both images (#11709).
 //
 // With 7 workers × 6144 MB the runner ran out and buildkit failed the step with
 // `ResourceExhausted: ... cannot allocate memory`, right after "Collecting page
 // data using 7 workers" — every Docker publish since 2026-08-22 23:14 UTC.
+// Lowering to 2 workers (#10060 / PR #11419) was not enough: it modeled the
+// per-process peak as an INFERENCE (`WORKER_PEAK_MB = 2560`, derived only from
+// "7 workers didn't fit") and assumed the parent process tracked the V8 heap
+// ceiling (`OMNIROUTE_BUILD_MEMORY_MB`) rather than its own RSS. The owner's
+// live VPS reproduction (issue #7518, dmesg OOM-killer report, 2026-08-24)
+// measured the real number directly: `next-build (v16) ... anon-rss:4522744kB`
+// (~4.5 GB) per process, independent of the NODE_OPTIONS heap flag — Turbopack
+// itself is native/Rust and compiles outside the V8 heap. With 2 workers that
+// keeps the publish pipeline failing at "Collecting page data using 2 workers"
+// (run 32907937950, 2026-08-25).
 //
-// This pins the budget so raising either knob has to be a deliberate change
-// that re-does the arithmetic, not a one-line bump that silently reds the
-// publish pipeline again.
+// This pins the budget on the MEASURED figure, applied uniformly to every
+// process (parent + workers) and to both images, so raising the worker count
+// has to be a deliberate change that re-does the arithmetic, not a one-line
+// bump that silently reds the publish pipeline again.
 
 const RUNNER_MEMORY_MB = 16 * 1024;
 // Leave room for buildkit, the snapshotter and page cache.
 const HEADROOM_FRACTION = 0.75;
-// Planning figure for one page-data worker's peak RSS. It is an INFERENCE, not
-// a measurement: 7 workers did not fit in 16 GB alongside the parent, which
-// puts the per-worker peak somewhere north of ~1.8 GB. 2.5 GB is that bound
-// rounded up, so the budget below stays conservative. If a future build OOMs
-// again with a worker count this test accepts, raise this number — do not
-// weaken the budget.
-const WORKER_PEAK_MB = 2560;
+// Measured (not inferred) peak RSS for a single Next/Turbopack build process —
+// parent or page-data worker alike — from the dmesg OOM-killer report above.
+// If a future build OOMs again, re-measure via dmesg before raising this
+// number — do not weaken the budget with another guess.
+const MEASURED_PROCESS_RSS_MB = 4500;
 
-const dockerfile = readFileSync(
-  fileURLToPath(new URL("../../Dockerfile", import.meta.url)),
-  "utf8"
-);
+const DOCKERFILES = [
+  { label: "Dockerfile", raw: readFileSync(fileURLToPath(new URL("../../Dockerfile", import.meta.url)), "utf8") },
+  { label: "Dockerfile.bun", raw: readFileSync(fileURLToPath(new URL("../../Dockerfile.bun", import.meta.url)), "utf8") },
+];
 
-function readArgDefault(name: string): number {
-  const match = dockerfile.match(new RegExp(`^ARG ${name}=(\\d+)$`, "m"));
-  assert.ok(match, `Dockerfile no longer declares ARG ${name}`);
+function readArgDefault(name: string, label: string): number {
+  const raw = DOCKERFILES.find((entry) => entry.label === label)!.raw;
+  const match = raw.match(new RegExp(`^ARG ${name}=(\\d+)$`, "m"));
+  assert.ok(match, `${label} no longer declares ARG ${name}`);
   return Number(match![1]);
 }
 
-test("the Docker build's worker pool is derived from OMNIROUTE_BUILD_WORKERS", () => {
-  // assert.ok(boolean), not assert.match — a failing assert.match dumps the
-  // whole Dockerfile into the report.
-  assert.ok(
-    /^ENV CIRCLE_NODE_TOTAL=\$\{OMNIROUTE_BUILD_WORKERS\}$/m.test(dockerfile),
-    "CIRCLE_NODE_TOTAL must stay wired to the build arg so a big builder can raise it"
-  );
-  assert.ok(
-    /^ENV NODE_OPTIONS="--max-old-space-size=\$\{OMNIROUTE_BUILD_MEMORY_MB\}"$/m.test(dockerfile),
-    "the build heap ceiling must stay wired to OMNIROUTE_BUILD_MEMORY_MB"
-  );
-});
+for (const { label } of DOCKERFILES) {
+  test(`the ${label} build's worker pool is derived from OMNIROUTE_BUILD_WORKERS`, () => {
+    // assert.ok(boolean), not assert.match — a failing assert.match dumps the
+    // whole Dockerfile into the report.
+    const raw = DOCKERFILES.find((entry) => entry.label === label)!.raw;
+    assert.ok(
+      /^ENV CIRCLE_NODE_TOTAL=\$\{OMNIROUTE_BUILD_WORKERS\}$/m.test(raw),
+      `${label}: CIRCLE_NODE_TOTAL must stay wired to the build arg so a big builder can raise it`
+    );
+    assert.ok(
+      /^ENV NODE_OPTIONS="--max-old-space-size=\$\{OMNIROUTE_BUILD_MEMORY_MB\}"$/m.test(raw),
+      `${label}: the build heap ceiling must stay wired to OMNIROUTE_BUILD_MEMORY_MB`
+    );
+  });
 
-test("worker count × per-process heap fits a 16 GB GitHub runner", () => {
-  const workerPool = readArgDefault("OMNIROUTE_BUILD_WORKERS");
-  const heapMb = readArgDefault("OMNIROUTE_BUILD_MEMORY_MB");
+  test(`worker count × measured per-process RSS fits a 16 GB GitHub runner (${label})`, () => {
+    const workerPool = readArgDefault("OMNIROUTE_BUILD_WORKERS", label);
 
-  // Next derives `workers = CIRCLE_NODE_TOTAL - 1`.
-  const workers = workerPool - 1;
-  assert.ok(workers >= 1, `CIRCLE_NODE_TOTAL=${workerPool} leaves no build workers`);
+    // Next derives `workers = CIRCLE_NODE_TOTAL - 1`.
+    const workers = workerPool - 1;
+    assert.ok(workers >= 1, `${label}: CIRCLE_NODE_TOTAL=${workerPool} leaves no build workers`);
 
-  // The parent `next build` process is the one that genuinely needs the raised
-  // ceiling (the webpack/turbopack production pass, #4076); the workers are
-  // budgeted at their inferred peak instead.
-  const worstCaseMb = heapMb + workers * WORKER_PEAK_MB;
-  const budgetMb = RUNNER_MEMORY_MB * HEADROOM_FRACTION;
-  assert.ok(
-    worstCaseMb <= budgetMb,
-    `parent ${heapMb} MB + ${workers} workers × ${WORKER_PEAK_MB} MB = ${worstCaseMb} MB ` +
-      `exceeds the ${budgetMb} MB budget on a ${RUNNER_MEMORY_MB} MB runner — the Docker ` +
-      `publish step dies with "ResourceExhausted: cannot allocate memory" during page-data ` +
-      `collection`
-  );
-});
+    // Every process — the parent `next build` process AND each page-data
+    // worker — is budgeted at the measured per-process RSS floor (see the file
+    // banner comment). The V8 heap ceiling (OMNIROUTE_BUILD_MEMORY_MB) bounds
+    // JS allocations but not Turbopack's native/Rust memory, so it cannot stand
+    // in for the parent process's real RSS.
+    const processes = workers + 1;
+    const worstCaseMb = processes * MEASURED_PROCESS_RSS_MB;
+    const budgetMb = RUNNER_MEMORY_MB * HEADROOM_FRACTION;
+    assert.ok(
+      worstCaseMb <= budgetMb,
+      `${label}: ${processes} processes (1 parent + ${workers} workers) × ${MEASURED_PROCESS_RSS_MB} MB ` +
+        `measured RSS = ${worstCaseMb} MB exceeds the ${budgetMb} MB budget on a ` +
+        `${RUNNER_MEMORY_MB} MB runner — the Docker publish step dies with "ResourceExhausted: ` +
+        `cannot allocate memory" during page-data collection`
+    );
+  });
 
-test("the worker pool does not oversubscribe the runner's 4 vCPU", () => {
-  const workers = readArgDefault("OMNIROUTE_BUILD_WORKERS") - 1;
-  assert.ok(workers <= 4, `${workers} workers oversubscribe a 4 vCPU runner`);
-});
+  test(`both images default to OMNIROUTE_BUILD_WORKERS=2 (1 page-data worker) (${label})`, () => {
+    // At OMNIROUTE_BUILD_WORKERS=2 → CIRCLE_NODE_TOTAL=2 → Next derives 1
+    // page-data worker, so 2 processes (parent + worker) × ~4.5 GB ≈ 9 GB fit
+    // the 12.288 GB (75%) budget on a 16 GB runner with headroom. At =3 → 2
+    // workers → 3 processes × 4.5 GB ≈ 13.5 GB, which exceeds it (measured
+    // per-process RSS, #7518). Raising this default must re-do the budget
+    // arithmetic and stay green on the test above (#11663).
+    assert.equal(
+      readArgDefault("OMNIROUTE_BUILD_WORKERS", label),
+      2,
+      `${label}: OMNIROUTE_BUILD_WORKERS must stay 2 (1 page-data worker)`
+    );
+  });
+
+  test(`the worker pool does not oversubscribe the runner's 4 vCPU (${label})`, () => {
+    const workers = readArgDefault("OMNIROUTE_BUILD_WORKERS", label) - 1;
+    assert.ok(workers <= 4, `${workers} workers oversubscribe a 4 vCPU runner`);
+  });
+}

tests/unit/electron-smoke-script.test.ts

@@ -7,6 +7,8 @@ import {
   FATAL_LOG_PATTERNS,
   LINUX_EXECUTABLE_NAMES,
   stopApp,
+  waitForDatabaseOpen,
+  DB_TOUCH_PATH,
 } from "../../scripts/dev/smoke-electron-packaged.mjs";
 
 test("electron smoke discovers the default Linux executable name", () => {
@@ -94,6 +96,46 @@ test("electron smoke flags a cold-restart fallback to the sql.js WASM driver", (
 test("electron smoke flags startup logs missing any driver selection line", () => {
   assert.throws(
     () => assertNativeDriverSelected("[electron] [server] listening on 20128"),
-    /no '\[DB\] Driver: \.\.\.' line/
+    /no database activity/
+  );
+});
+
+test("electron smoke waits for database-open evidence after touching a DB-backed endpoint", async () => {
+  assert.equal(DB_TOUCH_PATH, "/api/monitoring/health");
+  let logs = "[electron] [Server] [STARTUP] ready\n";
+  setTimeout(() => {
+    logs += "[electron] [Server] [DB] Added usage_history.combo_strategy column\n";
+  }, 60);
+  const seen = await waitForDatabaseOpen(() => logs, { timeoutMs: 2_000, pollMs: 20 });
+  assert.match(seen, /\[DB\] Added/);
+});
+
+test("electron smoke fails clearly when the database never opens", async () => {
+  await assert.rejects(
+    () =>
+      waitForDatabaseOpen(() => "[electron] [Server] [STARTUP] ready\n", {
+        timeoutMs: 120,
+        pollMs: 20,
+      }),
+    /logged no \[DB\]\/\[Migration\] startup line within 120ms/
+  );
+});
+
+test("electron smoke driver guard: native line, DB evidence and sql.js fallback", () => {
+  assert.doesNotThrow(() =>
+    assertNativeDriverSelected("[DB] Driver: better-sqlite3 | file: /tmp/x/storage.sqlite\n")
+  );
+  assert.doesNotThrow(() =>
+    assertNativeDriverSelected(
+      "[electron] [Server] [DB] Added call_logs.session_tag column\n[electron] [Server] [Migration] Applied: 046_database_settings\n"
+    )
+  );
+  assert.throws(
+    () => assertNativeDriverSelected("[DB] Driver: sql.js | file: /tmp/x/storage.sqlite\n"),
+    /sql\.js \(WASM\) driver/
+  );
+  assert.throws(
+    () => assertNativeDriverSelected("[STARTUP] nothing here\n"),
+    /no database activity/
   );
 });