fix: deployment boot smoke fails with 500 due to missing production env vars by BigSimmo · Pull Request #110 · BigSimmo/Database

BigSimmo · 2026-06-30T12:09:43Z

check:deployment-readiness was consistently timing out with "Unexpected status: 500" because instrumentation.ts's register() hook calls requireServerEnv() + requireOpenAIEnv() at next start, which throw when SUPABASE_SERVICE_ROLE_KEY and OPENAI_API_KEY are absent — causing Next.js to mark the server unhealthy and 500 every route including the trivial /api/local-project-id probe.

Summary

scripts/deployment-boot-smoke.mjs — pass placeholder fallbacks for SUPABASE_SERVICE_ROLE_KEY and OPENAI_API_KEY in the spawned server's env when real secrets aren't present. The smoke target (/api/local-project-id) uses neither; routes that do will still error if exercised. Real secrets are used when available.
scripts/deployment-boot-smoke.mjs — fix log cleanup ordering: rmSync was running inside the finally block before dumpLogTail could read the file. Moved cleanup out of finally into separate success/failure paths so server stderr is visible on future failures.

Verification

npm run check:deployment-readiness when deployment startup, hosting, or rollout behavior changed

Clinical Governance Preflight

Not applicable — CI tooling only, no clinical workflow or data path affected.

Notes

…design

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Database/src/app/api/answer/stream/route.ts

Lines 174 to 178 in 2993c37

confidence: "unsupported",
citations: [],
sources: [],
scope: scope ? { ...scope,queryMode: body.queryMode} : undefined,
sourceGovernanceWarnings: warnings,

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Resolves the `docs/outstanding-issues.md` conflict. Two independent causes: 1. Rows #98–#105 diverged. `main` carries the newer text (PR #1377 landed "Done 2026-07-29" outcomes and rewrote several summaries); this branch carried the pre-#1377 wording. Took `main`'s rows wholesale — the branch made no edits to that range, it simply forked before them. 2. `#108`/`#109` were allocated twice. `main` used them for the verified-landed branch deletions and the shallow-clone finding; this branch had used the same two ids for the design-system token manifest and the `ui-overlap` flake. The `issues:next-id` marker has no concurrency protection, which is exactly the failure the branch's own PR notes predicted. Renumbered this branch's two rows to #110/#111 and bumped the marker to 112. No content was dropped from either side; all 111 rows are unique. Also records #111 as done, since this branch is what fixes it: the ui-overlap inset measurement now retries inside `toPass` with the 2px symmetry tolerance and the assertions unchanged. Leaving it open with a "Next: apply the retry shape" action would have re-queued work this PR already did.

(#1391) Follow-ups to #1375 (Clinical Sky design system), which merged before these landed. `text-4xs` was dead on main. #1375 retired the `--text-4xs` token, so Tailwind emits no such rule and every remaining `text-4xs` class was a silent no-op with the text falling back to inherited size. Two files carrying it landed from main while #1375 was in flight and were dead on arrival. Repointed to `text-3xs`, the 10px floor, and guarded: the design-token contract now fails if any tracked file under `src/` references the retired class outside a comment. Mockups are deliberately not exempt — a dead utility breaks a mockup exactly as it breaks production. Six hydration races fixed at the source. In this app visible never implies interactive: the server-rendered tree paints before React owns it, so a single un-retried action asserted once is a coin flip under load. Every fix retries the action together with the effect it should produce, so a swallowed first attempt retries while a genuine regression still fails. Both retries added to ui-smoke are idempotent, which review caught and which matters more than it looks. `toPass` schedules another attempt whenever the inner assertion's own deadline expires — which can happen after the click already landed. Without a guard, `openGuide` clicked a Settings trigger the modal was already covering, and the mode-menu retry clicked a TOGGLE a second time, closing a menu that had just opened and oscillating until the budget ran out. The mobile branch needed a second guard: a swallowed Settings click leaves the phone menu open, so re-running `openMobileClinicalGuideMenu` would toggle it shut and then fail to find Settings inside it — meaning the <768px branch could not recover on retry at all. The ui-overlap phone-inset measurement now retries inside `toPass` with the 2px symmetry tolerance and the assertions byte-for-byte unchanged, so a genuinely asymmetric header still fails once the retry budget is spent. Documentation records that the intermediate font weights on the variable face are deliberate rather than drift, and that redefining Tailwind's own leading names silently retunes every existing call site. Also resolves an `issues:next-id` double-allocation: #108/#109 were claimed concurrently by two branches, so this branch's two rows are renumbered #110/#111 and the marker moved to 112. #111 is archived rather than left open, since this change is what closes it. RAG impact: no retrieval behaviour change — test robustness, two mockup class names, and docs only; nothing under `src/lib/rag/**`, clinical-search, ranking-config, the eval harness or the golden fixture is touched. Co-Authored-By: Claude Opus 5 <noreply@anthropic.com> Claude-Session: https://claude.ai/code/session_01FvU8z73P6TXUXoYBqN5K1P

…-30 re-sync) and capture #131 (five undefined CSS custom properties) Co-Authored-By: Claude Opus 5 <noreply@anthropic.com>

BigSimmo added 4 commits June 30, 2026 17:36

Refine answer formatting and search flow
cb8153a

Harden document label coverage and UI cleanup
67949de

refactor: component extraction polish and luxury black-first color re…
0eb2fbd
…design

Merge branch 'main' into codex/RAG_FIX
cf4fa67

Copilotstarted work on behalf of BigSimmo June 30, 2026 12:11 View session

fix: add GITHUB_TOKEN to gitleaks-action for PR scanning
c5696a4

Copilotfinished work on behalf of BigSimmo June 30, 2026 12:13

Copilotstarted work on behalf of BigSimmo June 30, 2026 12:17 View session

chatgpt-codex-connectorBot reviewed Jun 30, 2026
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Copilot stopped work on behalf of BigSimmo due to an error June 30, 2026 12:34
402 {"error":{"message":"You have exceeded your monthly quota","code":"quota_exceeded"}} (Request ID: 3BC2:2492F8:EA2D61:FCB9BD:6A43B7D5)

Copilotstarted work on behalf of BigSimmo June 30, 2026 12:37 View session

fix: pass placeholder creds to smoke server and fix log cleanup ordering
4ad7885

CopilotAI changed the title ~~refactor: component extraction polish and luxury black-first color redesign~~fix: deployment boot smoke fails with 500 due to missing production env varsJun 30, 2026

Copilotfinished work on behalf of BigSimmo June 30, 2026 12:49

Copilotstarted work on behalf of BigSimmo June 30, 2026 13:08 View session

test: align UI smoke expectations with current app modes and upload/p…
8e242ca
…df UI

Copilot stopped work on behalf of BigSimmo due to an error June 30, 2026 13:20
You have exceeded your monthly quota (Request ID: F839:29FC63:12E9DEA:1465A65:6A43C299)

chore: retrigger ci after bot test update
fcf686e

Copilotstarted work on behalf of BigSimmo June 30, 2026 13:27 View session

test: relax mobile settings fullscreen tolerance
8642ee7

Copilotfinished work on behalf of BigSimmo June 30, 2026 13:37

fix: address PR review feedback
2993c37

chatgpt-codex-connectorBot reviewed Jun 30, 2026
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Comment threadsrc/lib/reindex-pipeline.ts
Comment threadscripts/backfill-source-metadata.ts
Comment threadsrc/components/clinical-dashboard/DocumentManagerPanel.tsx
Comment threadsrc/lib/answer-render-policy.ts

Copilotstarted work on behalf of BigSimmo June 30, 2026 14:27 View session

Fix flaky fullscreen width assertion in mobile settings UI smoke test
7c0a2fb

Copilotfinished work on behalf of BigSimmo June 30, 2026 14:34

Copilotstarted work on behalf of BigSimmo June 30, 2026 14:34 View session

Copilotfinished work on behalf of BigSimmo June 30, 2026 14:35

Copilotstarted work on behalf of BigSimmo June 30, 2026 14:41 View session

Fix flaky mobile settings viewport assertion
1e653d3

Copilotfinished work on behalf of BigSimmo June 30, 2026 14:47

Copilotstarted work on behalf of BigSimmo June 30, 2026 15:23 View session

Stabilize mobile settings fullscreen UI assertion
dbeae81

Copilotfinished work on behalf of BigSimmo June 30, 2026 15:31

BigSimmo enabled auto-merge June 30, 2026 16:33

BigSimmo merged commit f5eb4cd into mainJun 30, 2026
6 checks passed

BigSimmo added a commit that referenced this pull request Jul 30, 2026
issues:close#110(design-system manifest regenerated by the 2026-07…
c5091e9
…-30 re-sync) and capture #131 (five undefined CSS custom properties) Co-Authored-By: Claude Opus 5 <noreply@anthropic.com>

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fix: deployment boot smoke fails with 500 due to missing production env vars - #110

fix: deployment boot smoke fails with 500 due to missing production env vars#110
BigSimmo merged 13 commits into
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codex/RAG_FIX

BigSimmo commented Jun 30, 2026•
edited by Copilot AI
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	confidence: "unsupported",
	citations: [],
	sources: [],
	scope: scope ? { ...scope,queryMode: body.queryMode} : undefined,
	sourceGovernanceWarnings: warnings,

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BigSimmo commented Jun 30, 2026•
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