chore(changelog): record release-green sequencing fix

changelog.d/maintenance/9838-release-green-pack-boot.md

@@ -0,0 +1 @@
+- Sequence the release-green tarball boot smoke after its package artifact build so clean-worktree validation cannot race a missing `dist/server.js`.

scripts/quality/validate-release-green.mjs

@@ -96,9 +96,7 @@ export function firstFailureLine(out) {
     .split("\n")
     .map((l) => l.trim())
     .filter(Boolean);
-  const hit = lines.find((l) =>
-    /✖|✗|not ok|AssertionError|error TS|FAIL|Error:|REGRESS/i.test(l)
-  );
+  const hit = lines.find((l) => /✖|✗|not ok|AssertionError|error TS|FAIL|Error:|REGRESS/i.test(l));
   return (hit || lines[lines.length - 1] || "failed").slice(0, 200);
 }
 
@@ -595,14 +593,6 @@ async function main() {
         args: ["run", "check:pack-artifact"],
         timeout: 20 * 60 * 1000,
       });
-      // WS1.2 (#7065 class): boot the REAL packed tarball from a clean install —
-      // the runtime gate structure checks cannot provide. Reuses the same dist/ build.
-      slow.push({
-        id: "pack-boot",
-        label: "Tarball boot-smoke (installed CLI serves /health)",
-        args: ["run", "check:pack-boot"],
-        timeout: 15 * 60 * 1000,
-      });
     }
     slow.forEach((g) => announce(`${g.label} [parallel]`));
     const slowResults = await Promise.all(
@@ -619,6 +609,41 @@ async function main() {
         detail: code === 0 ? "pass" : firstFailureLine(out),
       });
     });
+
+    if (WITH_BUILD) {
+      // WS1.2 (#7065 class): boot the REAL packed tarball from a clean install.
+      // check:pack-artifact is the builder for dist/ when staging is absent, so the
+      // boot smoke MUST run after it completes. Running both in the parallel wave
+      // races check:pack-boot against dist/server.js creation on clean worktrees.
+      const packArtifactIndex = slow.findIndex((g) => g.id === "pack-artifact");
+      const packArtifactResult = slowResults[packArtifactIndex];
+      const bootLabel = "Tarball boot-smoke (installed CLI serves /health)";
+
+      if (!packArtifactResult || packArtifactResult.code !== 0) {
+        const out = "skipped because package-artifact did not produce a valid dist/ build";
+        saveGateLog("pack-boot", out);
+        record({
+          id: "pack-boot",
+          label: bootLabel,
+          kind: "hard",
+          ok: false,
+          detail: out,
+        });
+      } else {
+        announce(bootLabel);
+        const { code, out } = await runAsync(npmCmd, ["run", "check:pack-boot"], {
+          timeout: 15 * 60 * 1000,
+        });
+        saveGateLog("pack-boot", out);
+        record({
+          id: "pack-boot",
+          label: bootLabel,
+          kind: "hard",
+          ok: code === 0,
+          detail: code === 0 ? "pass" : firstFailureLine(out),
+        });
+      }
+    }
   } else if (WITH_BUILD) {
     // --with-build without the suites (--quick): still verify the package artifact.
     const { code, out } = await runAsync(npmCmd, ["run", "check:pack-artifact"], {

tests/unit/validate-release-green.test.ts

@@ -22,16 +22,12 @@ const extract = extractCiGates as (
 ) => { id: string; job: string; args: string[]; env?: Record<string, string> }[];
 
 test("eslintCounts sums errors + warnings across files", () => {
-  const parsed = [
-    { errorCount: 2, warningCount: 5 },
-    { errorCount: 0, warningCount: 3 },
-    {},
-  ];
+  const parsed = [{ errorCount: 2, warningCount: 5 }, { errorCount: 0, warningCount: 3 }, {}];
   assert.deepEqual(eslintCounts(parsed), { errors: 2, warnings: 8 });
 });
 
 test("parseEslintJson tolerates a leading non-JSON banner", () => {
-  const out = "npm warn something\n[{\"errorCount\":0,\"warningCount\":1}]";
+  const out = 'npm warn something\n[{"errorCount":0,"warningCount":1}]';
   assert.deepEqual(parseEslintJson(out), [{ errorCount: 0, warningCount: 1 }]);
   assert.equal(parseEslintJson("no json here"), null);
 });
@@ -52,8 +48,14 @@ test("parseEslintJson tolerates ESLint's trailing unpruned-suppressions stderr s
 });
 
 test("parseCognitiveCount reads the gate's count (en + pt)", () => {
-  assert.equal(parseCognitiveCount("[cognitive-complexity] 797 function(s) exceed the threshold (15)."), 797);
-  assert.equal(parseCognitiveCount("[cognitive-complexity] REGRESSÃO — 801 violações > baseline 797"), 801);
+  assert.equal(
+    parseCognitiveCount("[cognitive-complexity] 797 function(s) exceed the threshold (15)."),
+    797
+  );
+  assert.equal(
+    parseCognitiveCount("[cognitive-complexity] REGRESSÃO — 801 violações > baseline 797"),
+    801
+  );
   assert.equal(parseCognitiveCount("no number"), null);
 });
 
@@ -175,8 +177,16 @@ test("pre-flight wires the test-masking PR-context gate against origin/main (v3.
   );
   // run() must honor a per-gate env override so GITHUB_BASE_REF actually reaches the child
   // (routed through buildGateEnv since the --hermetic scrub was added).
-  assert.match(src, /env:\s*buildGateEnv\(opts\.env\)/, "run() must merge opts.env into the child env");
-  assert.match(src, /\.\.\.\(extra \|\| \{\}\)/, "buildGateEnv must spread the per-gate env override");
+  assert.match(
+    src,
+    /env:\s*buildGateEnv\(opts\.env\)/,
+    "run() must merge opts.env into the child env"
+  );
+  assert.match(
+    src,
+    /\.\.\.\(extra \|\| \{\}\)/,
+    "buildGateEnv must spread the per-gate env override"
+  );
 });
 
 test("pre-flight --hermetic scrubs the live-test trigger vars (2026-07-05 false-positive fix)", async () => {
@@ -214,6 +224,27 @@ test("pre-flight runs the slow suites CONCURRENTLY (v3.8.45 perf — was ~1h ser
   assert.match(src, /slow\.forEach\([\s\S]*?saveGateLog\(g\.id/, "each slow gate persists its log");
 });
 
+test("pre-flight runs tarball boot only after the package artifact builder completes", async () => {
+  const fs = await import("node:fs");
+  const src = fs.readFileSync(
+    new URL("../../scripts/quality/validate-release-green.mjs", import.meta.url),
+    "utf8"
+  );
+  const parallelWave = src.indexOf("const slowResults = await Promise.all");
+  const packBoot = src.indexOf('id: "pack-boot"');
+
+  assert.ok(parallelWave >= 0, "the parallel slow-gate wave must exist");
+  assert.ok(
+    packBoot > parallelWave,
+    "pack-boot must be declared after the parallel artifact build"
+  );
+  assert.match(
+    src,
+    /packArtifactResult[\s\S]*?check:pack-boot/,
+    "pack-boot must be explicitly sequenced from the package-artifact result"
+  );
+});
+
 // ─── --full-ci gate extraction (P0, v3.8.46 post-mortem) ─────────────────────
 
 const CI_FIXTURE = `
@@ -259,7 +290,11 @@ test("extractCiGates: pulls npm-run gate steps from the ci.yml gate jobs only",
   assert.ok(ids.includes("check:docs-all") && ids.includes("check:docs-symbols"), "multi-line run");
   // …and NON-gate steps + jobs outside the gate set are ignored.
   assert.ok(!ids.includes("build") && !ids.some((i) => i.startsWith("test:")), "no build/test-run");
-  assert.equal(gates.find((g) => g.job === "test-unit"), undefined, "test-unit job is not scanned");
+  assert.equal(
+    gates.find((g) => g.job === "test-unit"),
+    undefined,
+    "test-unit job is not scanned"
+  );
 });
 
 test("extractCiGates: preserves `-- <args>` so ratchet flags reach the script", () => {
@@ -272,7 +307,10 @@ test("extractCiGates: preserves `-- <args>` so ratchet flags reach the script",
 test("extractCiGates: skips the non-local gates (pr-evidence, codeql-ratchet)", () => {
   const ids = extract(CI_FIXTURE).map((g) => g.id);
   assert.ok(!ids.includes("check:pr-evidence"), "pr-evidence needs a PR body — skipped");
-  assert.ok(!ids.includes("check:codeql-ratchet"), "codeql-ratchet is a remote-main check — skipped");
+  assert.ok(
+    !ids.includes("check:codeql-ratchet"),
+    "codeql-ratchet is a remote-main check — skipped"
+  );
   assert.ok(FULL_CI_SKIP.has("check:pr-evidence") && FULL_CI_SKIP.has("check:codeql-ratchet"));
 });
 
@@ -295,10 +333,7 @@ test("extractCiGates: attaches GITHUB_BASE_REF=main env to test-masking + de-dup
 
 test("extractCiGates: the REAL ci.yml yields the base-reds that leaked in v3.8.46", async () => {
   const fs = await import("node:fs");
-  const yaml = fs.readFileSync(
-    new URL("../../.github/workflows/ci.yml", import.meta.url),
-    "utf8"
-  );
+  const yaml = fs.readFileSync(new URL("../../.github/workflows/ci.yml", import.meta.url), "utf8");
   const ids = new Set(extract(yaml).map((g) => g.id));
   // The exact gates that leaked to the v3.8.46 release PR because the pre-flight
   // never ran them — --full-ci now reproduces every one.