fix: validate configured OpenCode binary (#1120)

* Validate configured OpenCode binary

* fix: keep WSL OpenCode startup failures retryable

Avoids misclassifying transient WSL resolution failures as invalid binary config
Adds regression coverage for WSL strict-mode handling
Cleans up temporary test directories
Fix for #1119 issue

packages/web/server/lib/opencode/env-runtime.js

@@ -875,6 +875,51 @@ export const createOpenCodeEnvRuntime = (deps) => {
     }
   };
 
+  const isMacOpenCodeAppBundlePath = (candidate) => {
+    if (process.platform !== 'darwin' || typeof candidate !== 'string') {
+      return false;
+    }
+    return /\/OpenCode\.app\/Contents\/MacOS\/(?:OpenCode|opencode-cli)$/i.test(candidate);
+  };
+
+  const createConfiguredOpencodeBinaryError = (raw, normalized) => {
+    const configured = typeof raw === 'string' ? raw.trim() : '';
+    const candidate = typeof normalized === 'string' && normalized.trim().length > 0 ? normalized.trim() : configured;
+    const messageSuffix = 'OpenChamber needs the standalone opencode CLI. Install it and set settings.opencodeBinary to the CLI path, for example ~/.opencode/bin/opencode, or leave the setting empty to use PATH lookup.';
+    const error = (() => {
+      if (isMacOpenCodeAppBundlePath(candidate) || isMacOpenCodeAppBundlePath(configured)) {
+        return new Error(`Configured OpenCode binary points at the macOS desktop app bundle, not the CLI: ${candidate}. ${messageSuffix}`);
+      }
+
+      try {
+        const configuredStat = fs.statSync(configured);
+        if (configuredStat.isDirectory()) {
+          return new Error(`Configured OpenCode binary directory does not contain an executable ${process.platform === 'win32' ? 'opencode.exe' : 'opencode'}: ${configured}. ${messageSuffix}`);
+        }
+      } catch {
+      }
+
+      try {
+        const stat = fs.statSync(candidate);
+        if (stat.isDirectory()) {
+          return new Error(`Configured OpenCode binary directory does not contain an executable ${process.platform === 'win32' ? 'opencode.exe' : 'opencode'}: ${candidate}. ${messageSuffix}`);
+        }
+        if (!stat.isFile()) {
+          return new Error(`Configured OpenCode binary is not a file: ${candidate}. ${messageSuffix}`);
+        }
+        return new Error(`Configured OpenCode binary is not executable: ${candidate}. ${messageSuffix}`);
+      } catch {
+        return new Error(`Configured OpenCode binary not found: ${candidate}. ${messageSuffix}`);
+      }
+    })();
+    error.code = 'OPENCODE_BINARY_INVALID';
+    return error;
+  };
+
+  const createConfiguredWslOpencodeError = (raw) => new Error(
+    `Configured settings.opencodeBinary uses WSL but OpenChamber could not resolve a WSL OpenCode command: ${raw}. Ensure WSL is available and opencode is installed in the configured distro.`
+  );
+
   const normalizeOpencodeBinarySetting = (raw) => {
     if (typeof raw !== 'string') {
       return null;
@@ -896,7 +941,8 @@ export const createOpenCodeEnvRuntime = (deps) => {
     return trimmed;
   };
 
-  const applyOpencodeBinaryFromSettings = async () => {
+  const applyOpencodeBinaryFromSettings = async (options = {}) => {
+    const strict = options?.strict === true;
     try {
       const settings = await readSettingsFromDiskMigrated();
       if (!settings || typeof settings !== 'object') {
@@ -932,6 +978,9 @@ export const createOpenCodeEnvRuntime = (deps) => {
         if (applied) {
           return applied;
         }
+        if (strict) {
+          throw createConfiguredWslOpencodeError(raw);
+        }
       }
 
       if (process.platform === 'win32' && (isWslExecutableValue(raw) || isWslExecutableValue(normalized || ''))) {
@@ -945,9 +994,12 @@ export const createOpenCodeEnvRuntime = (deps) => {
         if (applied) {
           return applied;
         }
+        if (strict) {
+          throw createConfiguredWslOpencodeError(raw);
+        }
       }
 
-      if (normalized && isExecutable(normalized)) {
+      if (normalized && isExecutable(normalized) && !isMacOpenCodeAppBundlePath(normalized)) {
         clearWslOpencodeResolution();
         process.env.OPENCODE_BINARY = normalized;
         prependToPath(path.dirname(normalized));
@@ -958,9 +1010,15 @@ export const createOpenCodeEnvRuntime = (deps) => {
       }
 
       if (raw) {
+        if (strict) {
+          throw createConfiguredOpencodeBinaryError(raw, normalized);
+        }
         console.warn(`Configured settings.opencodeBinary is not executable: ${raw}`);
       }
-    } catch {
+    } catch (error) {
+      if (strict) {
+        throw error;
+      }
     }
 
     return null;

packages/web/server/lib/opencode/env-runtime.test.js

@@ -0,0 +1,114 @@
+import fs from 'node:fs';
+import os from 'node:os';
+import path from 'node:path';
+import { afterEach, describe, expect, it } from 'vitest';
+import { createOpenCodeEnvRuntime } from './env-runtime.js';
+
+const originalOpencodeBinary = process.env.OPENCODE_BINARY;
+const originalPlatform = process.platform;
+const tempDirs = [];
+
+const createTempDir = (prefix) => {
+  const dir = fs.mkdtempSync(path.join(os.tmpdir(), prefix));
+  tempDirs.push(dir);
+  return dir;
+};
+
+const setPlatform = (platform) => {
+  Object.defineProperty(process, 'platform', {
+    value: platform,
+  });
+};
+
+afterEach(() => {
+  Object.defineProperty(process, 'platform', {
+    value: originalPlatform,
+  });
+
+  for (const dir of tempDirs.splice(0)) {
+    fs.rmSync(dir, { recursive: true, force: true });
+  }
+
+  if (typeof originalOpencodeBinary === 'string') {
+    process.env.OPENCODE_BINARY = originalOpencodeBinary;
+    return;
+  }
+  delete process.env.OPENCODE_BINARY;
+});
+
+const createRuntime = (settings) => {
+  const state = {
+    cachedLoginShellEnvSnapshot: null,
+    resolvedOpencodeBinary: null,
+    resolvedOpencodeBinarySource: null,
+    useWslForOpencode: false,
+    resolvedWslBinary: null,
+    resolvedWslOpencodePath: null,
+    resolvedWslDistro: null,
+    resolvedNodeBinary: null,
+    resolvedBunBinary: null,
+    managedOpenCodeShellEnvSnapshot: null,
+  };
+
+  const runtime = createOpenCodeEnvRuntime({
+    state,
+    normalizeDirectoryPath: (value) => value,
+    readSettingsFromDiskMigrated: async () => settings,
+    ENV_CONFIGURED_OPENCODE_WSL_DISTRO: null,
+  });
+
+  return { runtime, state };
+};
+
+describe('OpenCode env runtime', () => {
+  it('throws a specific error for a missing configured OpenCode binary in strict mode', async () => {
+    const { runtime } = createRuntime({ opencodeBinary: '/missing/opencode' });
+
+    await expect(runtime.applyOpencodeBinaryFromSettings({ strict: true })).rejects.toMatchObject({
+      code: 'OPENCODE_BINARY_INVALID',
+      message: expect.stringContaining('Configured OpenCode binary not found: /missing/opencode'),
+    });
+  });
+
+  it('throws a specific error for a configured directory without an executable CLI in strict mode', async () => {
+    const dir = createTempDir('openchamber-opencode-dir-');
+    const { runtime } = createRuntime({ opencodeBinary: dir });
+
+    await expect(runtime.applyOpencodeBinaryFromSettings({ strict: true })).rejects.toMatchObject({
+      code: 'OPENCODE_BINARY_INVALID',
+      message: expect.stringContaining('Configured OpenCode binary directory does not contain an executable'),
+    });
+  });
+
+  it('applies a valid configured executable OpenCode binary', async () => {
+    const dir = createTempDir('openchamber-opencode-bin-');
+    const binary = path.join(dir, 'opencode');
+    fs.writeFileSync(binary, '#!/bin/sh\nexit 0\n');
+    fs.chmodSync(binary, 0o755);
+    const { runtime, state } = createRuntime({ opencodeBinary: binary });
+
+    await expect(runtime.applyOpencodeBinaryFromSettings({ strict: true })).resolves.toBe(binary);
+    expect(process.env.OPENCODE_BINARY).toBe(binary);
+    expect(state.resolvedOpencodeBinary).toBe(binary);
+    expect(state.resolvedOpencodeBinarySource).toBe('settings');
+  });
+
+  it.runIf(process.platform === 'darwin')('rejects known macOS OpenCode app bundle executable paths', async () => {
+    const { runtime } = createRuntime({ opencodeBinary: '/Applications/OpenCode.app/Contents/MacOS/OpenCode' });
+
+    await expect(runtime.applyOpencodeBinaryFromSettings({ strict: true })).rejects.toMatchObject({
+      code: 'OPENCODE_BINARY_INVALID',
+      message: expect.stringContaining('macOS desktop app bundle'),
+    });
+  });
+
+  it('does not classify failed WSL resolution as an invalid configured binary in strict mode', async () => {
+    setPlatform('win32');
+    const { runtime } = createRuntime({ opencodeBinary: 'wsl:/usr/local/bin/opencode' });
+
+    await expect(runtime.applyOpencodeBinaryFromSettings({ strict: true })).rejects.toThrow('uses WSL');
+    await runtime.applyOpencodeBinaryFromSettings({ strict: true }).catch((error) => {
+      expect(error.code).toBeUndefined();
+    });
+  });
+});

packages/web/server/lib/opencode/lifecycle.js

@@ -289,7 +289,10 @@ export const createOpenCodeLifecycleRuntime = (deps) => {
 
       const onExit = (code, signal) => {
         const reason = signal ? `signal ${signal}` : `code ${code}`;
-        finish(reject, new Error(`OpenCode exited with ${reason}. ${formatCapturedOutput({ stdout, stderr })}`));
+        const appBundleHint = process.platform === 'darwin' && /\/OpenCode\.app\/Contents\/MacOS\/(?:OpenCode|opencode-cli)$/i.test(binary)
+          ? ' The configured binary appears to point at the macOS desktop app bundle; OpenChamber needs the standalone opencode CLI.'
+          : '';
+        finish(reject, new Error(`OpenCode process exited before serving with ${reason}. Binary used: ${binary}.${appBundleHint} ${formatCapturedOutput({ stdout, stderr })}`));
       };
 
       const onError = (error) => {
@@ -425,7 +428,7 @@ export const createOpenCodeLifecycleRuntime = (deps) => {
         : `Starting OpenCode on allocated port ${spawnPort}...`
     );
 
-    await applyOpencodeBinaryFromSettings();
+    await applyOpencodeBinaryFromSettings({ strict: true });
     ensureOpencodeCliEnv();
     const openCodePassword = await ensureLocalOpenCodeServerPassword({ rotateManaged: true });
     const envPath = typeof buildManagedOpenCodePath === 'function'
@@ -493,6 +496,9 @@ export const createOpenCodeLifecycleRuntime = (deps) => {
         return await startOpenCodeOnce();
       } catch (error) {
         lastError = error;
+        if (error?.code === 'OPENCODE_BINARY_INVALID') {
+          break;
+        }
         if (attempt >= START_OPEN_CODE_MAX_ATTEMPTS) {
           break;
         }

packages/web/server/lib/opencode/lifecycle.test.js

@@ -170,7 +170,7 @@ describe('OpenCode lifecycle', () => {
     await server.close();
   });
 
-  it('reports the exit signal when managed OpenCode exits before becoming ready', async () => {
+  it('reports the binary when managed OpenCode exits before becoming ready', async () => {
     delete process.env.OPENCODE_BINARY;
     const firstChild = createMockChild();
     const secondChild = createMockChild();
@@ -189,10 +189,26 @@ describe('OpenCode lifecycle', () => {
 
     const runtime = createRuntime();
 
-    await expect(runtime.startOpenCode()).rejects.toThrow('OpenCode exited with signal SIGTERM. No stdout/stderr captured');
+    await expect(runtime.startOpenCode()).rejects.toThrow('OpenCode process exited before serving with signal SIGTERM. Binary used: opencode. No stdout/stderr captured');
     expect(spawnMock).toHaveBeenCalledTimes(2);
   });
 
+  it('does not retry managed startup when the configured OpenCode binary is invalid', async () => {
+    delete process.env.OPENCODE_BINARY;
+    const error = new Error('Configured OpenCode binary not found: /missing/opencode');
+    error.code = 'OPENCODE_BINARY_INVALID';
+    const applyOpencodeBinaryFromSettings = vi.fn(async () => {
+      throw error;
+    });
+
+    const runtime = createRuntime({ applyOpencodeBinaryFromSettings });
+
+    await expect(runtime.startOpenCode()).rejects.toThrow('Configured OpenCode binary not found: /missing/opencode');
+    expect(applyOpencodeBinaryFromSettings).toHaveBeenCalledTimes(1);
+    expect(applyOpencodeBinaryFromSettings).toHaveBeenCalledWith({ strict: true });
+    expect(spawnMock).not.toHaveBeenCalled();
+  });
+
   it('retries managed OpenCode startup once after a pre-ready exit', async () => {
     delete process.env.OPENCODE_BINARY;
     const firstChild = createMockChild();