fix(cli): use build plugin to redirect morphsdk ESM barrel to CJS

packages/opencode/script/build.ts

@@ -287,10 +287,24 @@ for (const item of targets) {
   const bunfsRoot = item.os === "win32" ? "B:/~BUN/root/" : "/$bunfs/root/"
   const workerRelativePath = path.relative(dir, parserWorker).replaceAll("\\", "/")
 
+  // kilocode_change start - redirect @morphllm/morphsdk ESM barrel to self-contained CJS bundle
+  // Bun 1.3.14 (with conditions:["browser"]) resolves via the "import" condition, pulling in the
+  // pre-split ESM barrel (client.js) whose 52 chunk-*.js side-imports make the ESM splitter emit
+  // invalid minified output: SyntaxError: Exported binding 'G9' needs to refer to a top-level...
+  // Redirecting onResolve to client.cjs (2300-line self-contained CJS bundle) bypasses the splitter.
+  const morphsdkCjsPlugin: import("bun").BunPlugin = {
+    name: "morphsdk-cjs",
+    setup(build) {
+      build.onResolve({ filter: /^@morphllm\/morphsdk\/tools\/warp-grep\/client$/ }, () => ({
+        path: require.resolve("@morphllm/morphsdk/dist/tools/warp_grep/client.cjs"),
+      }))
+    },
+  }
+  // kilocode_change end
   await Bun.build({
     conditions: ["browser"],
     tsconfig: "./tsconfig.json",
-    plugins: [plugin], // kilocode_change
+    plugins: [plugin, morphsdkCjsPlugin], // kilocode_change
     // kilocode_change start - skip sourcemaps for release builds (each .js.map adds ~50 MB per target → ~600 MB total)
     sourcemap: Script.release ? "none" : "external",
     // kilocode_change end

packages/opencode/src/kilocode/compat/morphsdk.ts

@@ -1,42 +1,29 @@
-import { createRequire } from "module"
-
-// Force Bun to load @morphllm/morphsdk/tools/warp-grep/client via its self-contained
-// CJS bundle instead of the pre-split ESM barrel.
-//
-// WHY THIS EXISTS
-// ---------------
-// @morphllm/morphsdk ships a pre-split ESM distribution:
-//   dist/tools/warp_grep/client.js  (805 bytes, barrel)
-//     └─ imports from ../../chunk-P7G3CJB2.js
-//     └─ side-effects ../../chunk-63VHBANJ.js ... (12 more chunks, 52 total)
-//
-// When Bun bundles the CLI with `splitting: true + minify: true`, it merges
-// these external pre-split chunks into its own chunk graph. Bun 1.3.14 intermittently
-// generates invalid minified ESM in that process:
-//
+// kilocode_change - new file
+// Re-exports from @morphllm/morphsdk/tools/warp-grep/client.
+//
+// WHY THIS INDIRECTION EXISTS
+// ----------------------------
+// @morphllm/morphsdk ships a pre-split ESM distribution for this path:
+//   dist/tools/warp_grep/client.js  (805-byte barrel)
+//     └─ imports from ../../chunk-P7G3CJB2.js ... (52 total pre-split chunks)
+//
+// Bun 1.3.14 bundling with `conditions: ["browser"]` resolves via the "import" condition
+// (ESM barrel) even inside createRequire() calls. When its ESM splitter merges those
+// external pre-split chunks into the bundle, it generates invalid minified output:
 //   SyntaxError: Exported binding 'G9' needs to refer to a top-level declared variable.
 //
-// The error is non-deterministic (Bun's parallel bundler uses different orderings
-// per run), so the build sometimes succeeds and sometimes fails on Windows x64.
-//
-// The CJS bundle (client.cjs, ~2300 lines) is fully self-contained with no external
-// chunk imports. `createRequire` lets Bun inline the CJS module directly without
-// running it through the ESM splitter.
+// FIX: script/build.ts adds a morphsdkCjsPlugin (onResolve) that redirects this module
+// specifier to client.cjs — a fully self-contained CJS bundle (~2300 lines, no chunk-*.js
+// imports). The plugin runs at bundle time before the ESM splitter is invoked.
 //
 // HOW TO DETECT THIS FOR FUTURE DEPS
-// -----------------------------------
-// If a new dependency causes `SyntaxError: Exported binding '...' needs to refer to
-// a top-level declared variable` in release builds, check whether its ESM entry point
-// is a barrel that re-imports from internal `chunk-*.js` files:
+// ------------------------------------
+// If a new dependency causes the SyntaxError above in release builds, check whether its
+// ESM entry point is a barrel that re-imports from internal `chunk-*.js` files:
 //
 //   head -5 node_modules/<pkg>/dist/index.js
 //     → imports { ... } from "./chunk-XYZ123.js"  ← pre-split ESM
 //
-// If so, add a CJS bridge here and re-export from it instead of importing the package
-// directly. Always verify there is a `.cjs` (or CJS `main`) alternative.
-const req = createRequire(import.meta.url)
-
-// Type-cast via the package's own .d.ts so callers get full type safety.
-const mod = req("@morphllm/morphsdk/tools/warp-grep/client") as typeof import("@morphllm/morphsdk/tools/warp-grep/client")
+// If so, add a matching onResolve redirect to the CJS counterpart in build.ts.
 
-export const WarpGrepClient = mod.WarpGrepClient
+export { WarpGrepClient } from "@morphllm/morphsdk/tools/warp-grep/client"