Fix recurring EXC_BREAKPOINT/SIGTRAP crash (heap OOM from file-search-index rebuilds) + merge outstanding fix branches

handoffs/current.md

@@ -0,0 +1,142 @@
+# Current Handoff
+
+## Current Status
+
+Investigating a recurring `EXC_BREAKPOINT`/`SIGTRAP` crash on `CrBrowserMain`
+(main process). Confirmed root cause: `file-search-index.ts` rebuilds a
+~1.1M-entry home-directory index on an interval, and previously kept the old
+snapshot alive while building the new one — a multi-GB spike that blows any
+V8 heap ceiling. Fix is written, compiled, and packaged into the latest DMG,
+but **not yet confirmed working** — the last test run showed old (pre-fix)
+behavior, most likely because a stale process/build was tested rather than
+the new one. Branch `feat/fix-review-crash` also now contains two previously
+orphaned, unmerged upstream branches (see Decisions).
+
+## Completed Work
+
+- **`lastBuildError` leak** (`extension-runner.ts`): now cleared on successful
+  rebuild instead of growing forever.
+- **Window-manager worker fixes**: stopped silencing its stdout/stderr
+  (`main.ts`), which surfaced the real bug — `extract-file-icon` /
+  `node-gyp-build` weren't in `asarUnpack`, so `node-window-manager` failed to
+  load in packaged builds (`package.json`).
+- **V8 heap ceiling fix, corrected**: first attempt
+  (`app.commandLine.appendSwitch('js-flags', ...)`) confirmed NOT to reach the
+  main process (only affects Chromium renderer processes). Second attempt
+  (`v8.setFlagsFromString`) confirmed ineffective too (heap_size_limit is
+  fixed at isolate creation). Working fix: re-exec the process once with
+  `--js-flags=--max-old-space-size=4096` on argv (env-marker guarded against
+  looping). Verified live: process reports `~4096MB` limit.
+- **Diagnostics added** (`SC_HEAP_DEBUG=1` env gate): periodic
+  `process.memoryUsage()` log every 5 min, heap snapshot capture via
+  `Cmd+Alt+Shift+H` or `SIGUSR2`, written to `/tmp` (not `~/Library/Logs` —
+  that directory has repeatedly lost files minutes after being written,
+  cause unconfirmed, treat as unreliable for this investigation).
+- **Recovered two orphaned upstream branches** (both had open PRs, neither
+  merged into `main`, which itself is stalled at `2da7b9e`) and merged both
+  into `feat/fix-review-crash`, cleanly, no conflicts:
+  - `feat/Fix-shoutdown` (PR #630): LRU-cache extension bundles, stop
+    pre-warming window-manager-worker, non-blocking discovery, idle
+    transcription server shutdown (+ mid-request-kill bugfix), drain
+    in-flight extension/script work before quit (this one has its own ADR
+    diagnosing a *different* EXC_BREAKPOINT/SIGTRAP cause — a Node callback
+    completing after Electron tears down V8 on quit; not yet confirmed
+    whether it's still occurring separately from the FileIndex issue).
+  - `feat/feat-confetti` (PR #631): expanded tray menu (Settings, Extension
+    Store, Launch at Login, Check for Updates), Confetti/Fireworks/Snow/Rain
+    commands, esbuild moved to `optionalDependencies` (fixes `EBADPLATFORM`
+    on `npm install` for single-arch Macs).
+  - Pushed today's 4 relevant commits (lastBuildError, heap diagnostics,
+    window-manager stdio, heap-limit fix) onto `feat/Fix-shoutdown` and to
+    origin, updating PR #630 live (11 commits now).
+- **`file-search-index.ts` fix** (latest commit, root-cause fix):
+  - Old snapshot dropped (`activeIndex = null`) before building the new one,
+    instead of after — eliminates the double-memory rebuild spike. Trade-off:
+    search returns empty during the rebuild window.
+  - `MAX_INDEX_ENTRIES` 1.2M → 400k; `DEFAULT_REFRESH_INTERVAL_MS` 8min →
+    60min.
+  - Added a manual `system-rebuild-file-index` command
+    (`commands.ts`/`executeCommand`) for on-demand refresh.
+  - Compiled binary verified to contain `400000` (not `1200000`) — the fix is
+    genuinely in the shipped DMG.
+
+## Work In Progress
+
+- **Confirming the FileIndex fix actually resolves the crash.** Last test run
+  showed 1.1M entries and sub-60min interval rebuilds — i.e. old behavior —
+  strongly suggesting a stale process or pre-fix install was tested, not that
+  the fix failed. User was about to redo the test cleanly (kill all
+  processes, reinstall from `~/Downloads/SuperCmd-1.0.26-arm64.dmg`, verify
+  `grep -ao "400000" .../app.asar` before launching).
+
+## Pending Work
+
+1. Re-verify the FileIndex fix with a clean process + confirmed-current
+   build, ideally past the ~48–96min window where every prior crash occurred.
+2. If it still crashes: get another `[HeapDebug]`/`[FileIndex]` log + `.ips`
+   from `~/Library/Logs/DiagnosticReports/` (read it immediately, it may
+   disappear) and check whether the heap trend shows another single big
+   jump (another oversized structure) or a slow genuine leak this time.
+3. If it holds: consider whether `feat/Fix-shoutdown`'s quit-time race
+   condition (drain-before-quit, already merged) is a second, independent,
+   much rarer cause — no direct evidence yet that it's firing separately.
+4. Two open upstream PRs (#630, #631) are `MERGEABLE` but `BLOCKED` on
+   review — no CI configured on this repo, no human reviewer assigned.
+   `main` itself has been stalled at `2da7b9e` this whole time; consider
+   whether that's expected or itself a process gap worth raising.
+5. Optional, not started: `global.gc()` periodic-forcing was proposed as a
+   heap mitigation but deferred by user request ("ya veremos") in favor of
+   chasing the FileIndex root cause first.
+
+## Blockers
+
+- None technical. Confirmation is blocked only on the user's next test run.
+
+## Decisions
+
+- Bring both orphaned branches into `feat/fix-review-crash` rather than
+  leave them stranded or merge straight to `main` (user's call, asked
+  explicitly).
+- Accept a brief "search returns nothing" window during FileIndex rebuilds
+  in exchange for not doubling peak memory (user's call, picked this option
+  explicitly over alternatives).
+- Diagnostics write to `/tmp`, not `~/Library/Logs` — that directory has
+  been unreliable mid-session (files vanishing) independent of anything in
+  this codebase; don't rely on it for future debugging in this repo either.
+
+## Risks
+
+- The ~48–96min crash timing has been remarkably consistent across multiple
+  different fixes (heap ceiling raised, FileIndex capped) — if the next test
+  still crashes around that window, the FileIndex theory may be wrong or
+  incomplete, and the quit-time-race theory (already fixed via
+  drain-before-quit) or a third, unfound cause should be considered before
+  assuming "still the same bug."
+- `git log --oneline` output was momentarily misleading mid-session (looked
+  stale after a `cherry-pick --abort`) — cross-checked via `rev-parse`/
+  `cat-file` and it was fine, but worth using low-level plumbing commands to
+  double check if branch state ever looks wrong again in this repo.
+- Multiple stale/orphaned SuperCmd processes have repeatedly confused test
+  results this session (old tray menu, "app still runs after deleting it",
+  and likely the last FileIndex test). Always confirm zero running processes
+  and verify the installed binary's content (e.g. `grep -ao` a known string)
+  before trusting a test result in this project going forward.
+
+## Next Actions
+
+- Wait for user's clean re-test of the FileIndex fix.
+- Depending on result, either close out the crash investigation or resume
+  hunting (see Pending Work #2–3).
+
+## References
+
+- Crash reports (may vanish from disk, read immediately if consulted):
+  `~/Library/Logs/DiagnosticReports/SuperCmd-2026-07-{17,20,21}-*.ips`
+- `src/main/file-search-index.ts`, `src/main/extension-runner.ts`,
+  `src/main/main.ts`, `src/main/commands.ts`
+- Upstream: `SuperCmdLabs/SuperCmd` PR #630, PR #631
+- ADR (via `codebase-memory-mcp`, project
+  `Users-cgomez-orca-workspaces-SuperCmd-Fix-shoutdown`): quit-time-race
+  diagnosis for the drain-before-quit fix
+- Local DMG builds: `~/Downloads/SuperCmd-1.0.26-arm64.dmg` (rebuilt several
+  times today — always verify MD5/content before trusting a test against it)

package.json

@@ -42,8 +42,6 @@
   },
   "dependencies": {
     "@aptabase/electron": "^0.3.1",
-    "@esbuild/darwin-arm64": "0.19.12",
-    "@esbuild/darwin-x64": "0.19.12",
     "@phosphor-icons/react": "^2.1.10",
     "@raycast/api": "^1.104.5",
     "electron-builder-notarize": "^1.5.2",
@@ -57,6 +55,10 @@
     "react-dom": "^18.2.0",
     "transliteration": "^2.6.1"
   },
+  "optionalDependencies": {
+    "@esbuild/darwin-arm64": "0.19.12",
+    "@esbuild/darwin-x64": "0.19.12"
+  },
   "build": {
     "appId": "com.supercmd.app",
     "productName": "SuperCmd",
@@ -76,6 +78,8 @@
       "node_modules/@esbuild/**",
       "node_modules/node-edge-tts/**",
       "node_modules/node-window-manager/**",
+      "node_modules/extract-file-icon/**",
+      "node_modules/node-gyp-build/**",
       "node_modules/electron-liquid-glass/**"
     ],
     "files": [

scripts/measure-extension-bundle-cache.mjs

@@ -229,8 +229,7 @@ async function main() {
 
     const menuBar = await measure('repeated-menu-bar-background-prep', fixture.extDir, async () => {
       for (let i = 0; i < iterations; i++) {
-        const commands = runner
-          .discoverInstalledExtensionCommands()
+        const commands = (await runner.discoverInstalledExtensionCommands())
           .filter((command) => command.mode === 'menu-bar');
         assert.equal(commands.length, 1);
         const bundle = await runner.getExtensionBundle(commands[0].extName, commands[0].cmdName);

src/main/commands.ts

@@ -13,6 +13,7 @@
 import { app } from 'electron';
 import { exec, execFile, spawn } from 'child_process';
 import { promisify } from 'util';
+import { rebuildFileSearchIndex } from './file-search-index';
 import * as fs from 'fs';
 import * as path from 'path';
 import * as crypto from 'crypto';
@@ -67,6 +68,22 @@ const SHUTDOWN_ICON_DATA_URL = svgToBase64DataUrl(
   '<svg xmlns="http://www.w3.org/2000/svg" width="64" height="64" viewBox="0 0 64 64" fill="none"><defs><linearGradient id="sdBg" x1="12" y1="10" x2="52" y2="54" gradientUnits="userSpaceOnUse"><stop stop-color="#fca5a5" stop-opacity="0.7"/><stop offset="1" stop-color="#dc2626" stop-opacity="0.82"/></linearGradient></defs><rect x="8" y="8" width="48" height="48" rx="15" fill="url(#sdBg)"/><g transform="translate(18,18) scale(1.167)" stroke="rgba(255,255,255,0.92)" stroke-width="2" stroke-linecap="round" stroke-linejoin="round"><path d="M18.36 6.64a9 9 0 1 1-12.73 0"/><line x1="12" y1="2" x2="12" y2="12"/></g></svg>'
 );
 
+const CONFETTI_ICON_DATA_URL = svgToBase64DataUrl(
+  '<svg xmlns="http://www.w3.org/2000/svg" width="64" height="64" viewBox="0 0 64 64" fill="none"><defs><linearGradient id="cfBg" x1="12" y1="10" x2="52" y2="54" gradientUnits="userSpaceOnUse"><stop stop-color="#f0abfc" stop-opacity="0.7"/><stop offset="1" stop-color="#a21caf" stop-opacity="0.82"/></linearGradient></defs><rect x="8" y="8" width="48" height="48" rx="15" fill="url(#cfBg)"/><g transform="translate(18,18) scale(1.167)" stroke="rgba(255,255,255,0.92)" stroke-width="2" stroke-linecap="round" stroke-linejoin="round" fill="none"><path d="M4 20 12 6 20 10 8 16Z"/><path d="M12 6c1-1.2 2.6-1.8 4-1.4"/><circle cx="21" cy="3" r="0.9" fill="rgba(255,255,255,0.92)" stroke="none"/><circle cx="17" cy="1.5" r="0.9" fill="rgba(255,255,255,0.92)" stroke="none"/><circle cx="23" cy="7" r="0.9" fill="rgba(255,255,255,0.92)" stroke="none"/></g></svg>'
+);
+
+const FIREWORKS_ICON_DATA_URL = svgToBase64DataUrl(
+  '<svg xmlns="http://www.w3.org/2000/svg" width="64" height="64" viewBox="0 0 64 64" fill="none"><defs><linearGradient id="fwBg" x1="12" y1="10" x2="52" y2="54" gradientUnits="userSpaceOnUse"><stop stop-color="#fde047" stop-opacity="0.7"/><stop offset="1" stop-color="#a16207" stop-opacity="0.82"/></linearGradient></defs><rect x="8" y="8" width="48" height="48" rx="15" fill="url(#fwBg)"/><g transform="translate(18,18) scale(1.167)" stroke="rgba(255,255,255,0.92)" stroke-width="2" stroke-linecap="round" stroke-linejoin="round" fill="none"><line x1="12" y1="22" x2="12" y2="14"/><line x1="12" y1="2" x2="12" y2="6"/><line x1="5" y1="9" x2="8" y2="10.5"/><line x1="19" y1="9" x2="16" y2="10.5"/><line x1="7" y1="4" x2="9.5" y2="7"/><line x1="17" y1="4" x2="14.5" y2="7"/><circle cx="12" cy="10" r="1.1" fill="rgba(255,255,255,0.92)" stroke="none"/></g></svg>'
+);
+
+const SNOW_ICON_DATA_URL = svgToBase64DataUrl(
+  '<svg xmlns="http://www.w3.org/2000/svg" width="64" height="64" viewBox="0 0 64 64" fill="none"><defs><linearGradient id="snBg" x1="12" y1="10" x2="52" y2="54" gradientUnits="userSpaceOnUse"><stop stop-color="#a5f3fc" stop-opacity="0.7"/><stop offset="1" stop-color="#0e7490" stop-opacity="0.82"/></linearGradient></defs><rect x="8" y="8" width="48" height="48" rx="15" fill="url(#snBg)"/><g transform="translate(18,18) scale(1.167)" stroke="rgba(255,255,255,0.92)" stroke-width="2" stroke-linecap="round" stroke-linejoin="round"><line x1="12" y1="2" x2="12" y2="22"/><line x1="4.2" y1="7" x2="19.8" y2="17"/><line x1="19.8" y1="7" x2="4.2" y2="17"/></g></svg>'
+);
+
+const RAIN_ICON_DATA_URL = svgToBase64DataUrl(
+  '<svg xmlns="http://www.w3.org/2000/svg" width="64" height="64" viewBox="0 0 64 64" fill="none"><defs><linearGradient id="rnBg" x1="12" y1="10" x2="52" y2="54" gradientUnits="userSpaceOnUse"><stop stop-color="#a5b4fc" stop-opacity="0.7"/><stop offset="1" stop-color="#3730a3" stop-opacity="0.82"/></linearGradient></defs><rect x="8" y="8" width="48" height="48" rx="15" fill="url(#rnBg)"/><g transform="translate(18,18) scale(1.167)" stroke="rgba(255,255,255,0.92)" stroke-width="2" stroke-linecap="round" stroke-linejoin="round" fill="none"><path d="M17.5 19H9a7 7 0 1 1 6.71-9h1.79a4.5 4.5 0 1 1 0 9Z"/><line x1="8" y1="19" x2="6.5" y2="22"/><line x1="13" y1="19" x2="11.5" y2="22"/></g></svg>'
+);
+
 export interface CommandInfo {
   id: string;
   title: string;
@@ -129,19 +146,21 @@ function getCommandsDiskCachePath(): string {
   return commandsDiskCachePath;
 }
 
-function loadCommandsDiskCache(): CommandInfo[] | null {
+async function loadCommandsDiskCache(): Promise<CommandInfo[] | null> {
   try {
-    const raw = fs.readFileSync(getCommandsDiskCachePath(), 'utf-8');
+    const raw = await fs.promises.readFile(getCommandsDiskCachePath(), 'utf-8');
     const parsed = JSON.parse(raw) as { version: number; commands: CommandInfo[] };
     if (parsed?.version !== COMMANDS_DISK_CACHE_VERSION) return null;
     const cmds = parsed.commands;
-    // Re-attach icons from the per-app icon disk cache (fast file reads).
-    for (const cmd of cmds) {
-      if (cmd.path) {
-        const icon = getCachedIcon(cmd.path);
-        if (icon) cmd.iconDataUrl = icon;
-      }
-    }
+    // Re-attach icons from the per-app icon disk cache. Reading them
+    // concurrently (fs.promises, backed by libuv's threadpool) instead of one
+    // fs.readFileSync per command avoids serializing every icon read on the
+    // main thread right before the first window is created.
+    await Promise.all(cmds.map(async (cmd) => {
+      if (!cmd.path) return;
+      const icon = await getCachedIconAsync(cmd.path);
+      if (icon) cmd.iconDataUrl = icon;
+    }));
     return cmds;
   } catch {
     return null;
@@ -163,8 +182,8 @@ function saveCommandsDiskCache(commands: CommandInfo[]): void {
 }
 
 /** Call once after app.whenReady() to pre-populate the in-memory cache from disk. */
-export function initCommandsCache(): void {
-  const cmds = loadCommandsDiskCache();
+export async function initCommandsCache(): Promise<void> {
+  const cmds = await loadCommandsDiskCache();
   if (cmds) {
     cachedCommands = cmds;
     staleCommandsFallback = cmds;
@@ -207,6 +226,15 @@ function getCachedIcon(bundlePath: string): string | undefined {
   return undefined;
 }
 
+async function getCachedIconAsync(bundlePath: string): Promise<string | undefined> {
+  try {
+    const cacheFile = path.join(getIconCacheDir(), `${iconCacheKey(bundlePath)}.b64`);
+    return await fs.promises.readFile(cacheFile, 'utf-8');
+  } catch {
+    return undefined;
+  }
+}
+
 function setCachedIcon(bundlePath: string, dataUrl: string): void {
   try {
     const cacheFile = path.join(getIconCacheDir(), `${iconCacheKey(bundlePath)}.b64`);
@@ -1308,13 +1336,51 @@ async function discoverAndBuildCommands(): Promise<CommandInfo[]> {
       keywords: ['emoji', 'picker', 'trigger', 'smiley', 'emoticon'],
       category: 'system',
     },
+    {
+      id: 'system-confetti',
+      title: 'Confetti',
+      subtitle: 'Celebrate with a burst of confetti',
+      keywords: ['confetti', 'celebrate', 'party', 'fun', 'congrats', 'congratulations', 'celebration'],
+      iconDataUrl: CONFETTI_ICON_DATA_URL,
+      category: 'system',
+    },
+    {
+      id: 'system-fireworks',
+      title: 'Fireworks',
+      subtitle: 'Launch a fireworks show',
+      keywords: ['fireworks', 'rockets', 'celebrate', 'party', 'fun', 'show', 'pyrotechnics'],
+      iconDataUrl: FIREWORKS_ICON_DATA_URL,
+      category: 'system',
+    },
+    {
+      id: 'system-snow',
+      title: 'Snow',
+      subtitle: 'Let it snow on your screen',
+      keywords: ['snow', 'snowfall', 'winter', 'christmas', 'fun', 'weather'],
+      iconDataUrl: SNOW_ICON_DATA_URL,
+      category: 'system',
+    },
+    {
+      id: 'system-rain',
+      title: 'Rain',
+      subtitle: 'Make it rain on your screen',
+      keywords: ['rain', 'rainfall', 'storm', 'weather', 'fun'],
+      iconDataUrl: RAIN_ICON_DATA_URL,
+      category: 'system',
+    },
     {
       id: 'system-reset-launcher-position',
       title: 'Reset Launcher Position',
       keywords: ['reset', 'position', 'center', 'move', 'launcher', 'window', 'default'],
       iconDataUrl: RESET_POSITION_ICON_DATA_URL,
       category: 'system',
     },
+    {
+      id: 'system-rebuild-file-index',
+      title: 'Rebuild File Search Index',
+      keywords: ['rebuild', 'refresh', 'reindex', 'file', 'search', 'index', 'supercmd'],
+      category: 'system',
+    },
     {
       id: 'system-open-settings',
       title: 'SuperCmd Settings',
@@ -1849,7 +1915,7 @@ async function discoverAndBuildCommands(): Promise<CommandInfo[]> {
   // Installed community extensions
   let extensionCommands: CommandInfo[] = [];
   try {
-    extensionCommands = discoverInstalledExtensionCommands().map((ext) => ({
+    extensionCommands = (await discoverInstalledExtensionCommands()).map((ext) => ({
       id: ext.id,
       title: ext.title,
       subtitle: ext.extensionTitle,
@@ -2108,6 +2174,16 @@ export async function executeCommand(id: string): Promise<boolean> {
     }
   }
 
+  if (id === 'system-rebuild-file-index') {
+    try {
+      await rebuildFileSearchIndex('manual-command');
+      return true;
+    } catch (error) {
+      console.error('Failed to rebuild file search index:', error);
+      return false;
+    }
+  }
+
   // Use stale fallback when available to avoid blocking on a fresh discovery
   // while the cache is being rebuilt in the background.
   const commands = cachedCommands ?? staleCommandsFallback ?? await getAvailableCommands();