Fix/onboard spawnsync timeout

bin/lib/onboard.js

@@ -637,6 +637,12 @@ function summarizeProbeError(body, status) {
   return `HTTP ${status}: ${compact.slice(0, 200)}`;
 }
 
+/** True when spawnSync killed the child due to its timeout option. */
+function isSpawnTimeout(result) {
+  return result.error?.code === "ETIMEDOUT" ||
+    (result.status == null && result.signal === "SIGTERM");
+}
+
 function probeOpenAiLikeEndpoint(endpointUrl, model, apiKey) {
   const probes = [
     {
@@ -678,11 +684,16 @@ function probeOpenAiLikeEndpoint(endpointUrl, model, apiKey) {
       const result = spawnSync("bash", ["-c", cmd], {
         cwd: ROOT,
         encoding: "utf8",
+        timeout: 30_000,
         env: {
           ...process.env,
           NEMOCLAW_PROBE_API_KEY: apiKey,
         },
       });
+      if (isSpawnTimeout(result)) {
+        failures.push({ name: probe.name, httpStatus: 0, curlStatus: 1, message: "timed out" });
+        continue;
+      }
       const body = fs.existsSync(bodyFile) ? fs.readFileSync(bodyFile, "utf8") : "";
       const status = Number(String(result.stdout || "").trim());
       if (result.status === 0 && status >= 200 && status < 300) {
@@ -727,11 +738,15 @@ function probeAnthropicEndpoint(endpointUrl, model, apiKey) {
     const result = spawnSync("bash", ["-c", cmd], {
       cwd: ROOT,
       encoding: "utf8",
+      timeout: 30_000,
       env: {
         ...process.env,
         NEMOCLAW_PROBE_API_KEY: apiKey,
       },
     });
+    if (isSpawnTimeout(result)) {
+      return { ok: false, message: "timed out", failures: [{ name: "Anthropic Messages API", httpStatus: 0, curlStatus: 1, message: "timed out" }] };
+    }
     const body = fs.existsSync(bodyFile) ? fs.readFileSync(bodyFile, "utf8") : "";
     const status = Number(String(result.stdout || "").trim());
     if (result.status === 0 && status >= 200 && status < 300) {
@@ -867,11 +882,15 @@ function fetchNvidiaEndpointModels(apiKey) {
     const result = spawnSync("bash", ["-c", cmd], {
       cwd: ROOT,
       encoding: "utf8",
+      timeout: 30_000,
       env: {
         ...process.env,
         NEMOCLAW_PROBE_API_KEY: apiKey,
       },
     });
+    if (isSpawnTimeout(result)) {
+      return { ok: false, message: "timed out" };
+    }
     const body = fs.existsSync(bodyFile) ? fs.readFileSync(bodyFile, "utf8") : "";
     const status = Number(String(result.stdout || "").trim());
     if (result.status !== 0 || !(status >= 200 && status < 300)) {
@@ -920,11 +939,15 @@ function fetchOpenAiLikeModels(endpointUrl, apiKey) {
     const result = spawnSync("bash", ["-c", cmd], {
       cwd: ROOT,
       encoding: "utf8",
+      timeout: 30_000,
       env: {
         ...process.env,
         NEMOCLAW_PROBE_API_KEY: apiKey,
       },
     });
+    if (isSpawnTimeout(result)) {
+      return { ok: false, status: 0, message: "timed out" };
+    }
     const body = fs.existsSync(bodyFile) ? fs.readFileSync(bodyFile, "utf8") : "";
     const status = Number(String(result.stdout || "").trim());
     if (result.status !== 0 || !(status >= 200 && status < 300)) {
@@ -957,11 +980,15 @@ function fetchAnthropicModels(endpointUrl, apiKey) {
     const result = spawnSync("bash", ["-c", cmd], {
       cwd: ROOT,
       encoding: "utf8",
+      timeout: 30_000,
       env: {
         ...process.env,
         NEMOCLAW_PROBE_API_KEY: apiKey,
       },
     });
+    if (isSpawnTimeout(result)) {
+      return { ok: false, status: 0, message: "timed out" };
+    }
     const body = fs.existsSync(bodyFile) ? fs.readFileSync(bodyFile, "utf8") : "";
     const status = Number(String(result.stdout || "").trim());
     if (result.status !== 0 || !(status >= 200 && status < 300)) {
@@ -1223,6 +1250,7 @@ function pullOllamaModel(model) {
     cwd: ROOT,
     encoding: "utf8",
     stdio: "inherit",
+    timeout: 300_000,
     env: { ...process.env },
   });
   return result.status === 0;
@@ -1358,6 +1386,7 @@ function installOpenshell() {
     env: process.env,
     stdio: ["ignore", "pipe", "pipe"],
     encoding: "utf-8",
+    timeout: 120_000,
   });
   if (result.status !== 0) {
     const output = `${result.stdout || ""}${result.stderr || ""}`.trim();

test/onboard.test.js

@@ -1331,3 +1331,48 @@ const { setupInference } = require(${onboardPath});
   });
 
 });
+
+describe("spawnSync timeout safety", () => {
+  const onboardSrc = fs.readFileSync(
+    path.join(import.meta.dirname, "..", "bin", "lib", "onboard.js"),
+    "utf8"
+  );
+  const lines = onboardSrc.split("\n");
+
+  // Find every line that starts a spawnSync call, then scan ahead for the
+  // closing options object.  We collect the text from the spawnSync line
+  // through the next line containing only "});", which is the end of the
+  // options object in the codebase's formatting.
+  function collectSpawnBlocks() {
+    const blocks = [];
+    for (let i = 0; i < lines.length; i++) {
+      if (/spawnSync\(/.test(lines[i])) {
+        let block = lines[i];
+        for (let j = i + 1; j < lines.length; j++) {
+          block += "\n" + lines[j];
+          if (/^\s*\);/.test(lines[j]) || /^\s*\}\);/.test(lines[j])) break;
+        }
+        blocks.push({ line: i + 1, text: block });
+      }
+    }
+    return blocks;
+  }
+
+  const spawnBlocks = collectSpawnBlocks();
+
+  it("has non-sleep spawnSync calls to test", () => {
+    const actionable = spawnBlocks.filter(({ text }) => !/spawnSync\("sleep"/.test(text));
+    expect(actionable.length).toBeGreaterThan(0);
+  });
+
+  it("every spawnSync call that runs an external command includes a timeout", () => {
+    const missing = [];
+    for (const { line, text } of spawnBlocks) {
+      if (/spawnSync\("sleep"/.test(text)) continue;
+      if (!text.includes("timeout")) {
+        missing.push(`line ${line}: ${text.split("\n")[0].trim()}`);
+      }
+    }
+    expect(missing, `spawnSync calls missing timeout:\n${missing.join("\n")}`).toHaveLength(0);
+  });
+});