fix(sandbox): redact underscore-separated env names in wedge diagnostics

ci/source-architecture-budget.json

@@ -25,7 +25,7 @@
       "src/lib/messaging/channels/index.ts": 25,
       "src/lib/onboard/gateway-binding.ts": 52,
       "src/lib/runner.ts": 87,
-      "src/lib/security/redact.ts": 53,
+      "src/lib/security/redact.ts": 54,
       "src/lib/state/onboard-session.ts": 37,
       "src/lib/state/registry.ts": 101,
       "src/lib/state/state-root.ts": 21,

src/lib/actions/sandbox/gateway-wedge-diagnostics.test.ts

@@ -41,15 +41,24 @@ describe("collectGatewayWedgeDiagnostics wedge signature (#4710)", () => {
       stdout:
         "gateway startup failed: Authorization: Bearer abc.def.ghi rejected\n" +
         'gateway startup failed: api_key="nv-secret-123" invalid\n' +
-        "gateway startup failed: \u001b[31mboom\u001b[0m Process will stay alive\n",
+        "gateway startup failed: \u001b[31mboom\u001b[0m Process will stay alive\n" +
+        "gateway startup failed: env OPENAI_API_KEY=example-not-a-real-value-0001\n" +
+        "gateway startup failed: SLACK_BOT_TOKEN=example-not-a-real-value-0002\n" +
+        "Process will stay alive; TELEGRAM_BOT_TOKEN=example-not-a-real-value-0003\n",
       stderr: "",
     }));
     expect(lines[0]).toBe("gateway startup failed: Authorization: Bearer [REDACTED] rejected");
-    expect(lines[1]).toBe('gateway startup failed: api_key="[REDACTED] invalid');
+    expect(lines[1]).toBe('gateway startup failed: api_key="[REDACTED]" invalid');
     // Terminal escape sequences are stripped so sandbox output cannot forge
     // operator-terminal content.
     expect(lines[2]).toBe("gateway startup failed: [31mboom[0m Process will stay alive");
     expect(lines[2]).not.toContain("\u001b");
+    // Underscore-separated credential env names need the shared redactor: `\b`
+    // does not match between `_` and a word character, so the local patterns
+    // above never reach the assignment.
+    expect(lines[3]).toBe("gateway startup failed: env OPENAI_API_KEY=<REDACTED>");
+    expect(lines[4]).toBe("gateway startup failed: SLACK_BOT_TOKEN=<REDACTED>");
+    expect(lines[5]).toBe("Process will stay alive; TELEGRAM_BOT_TOKEN=<REDACTED>");
   });
 });
 
@@ -64,6 +73,21 @@ describe("sanitizeWedgeLogLine", () => {
     );
   });
 
+  it.each([
+    ['OPENAI_API_KEY="opaque api key value"', "opaque api key value"],
+    ["SERVICE_TOKEN='opaque token value'", "opaque token value"],
+    ['DATABASE_PASSWORD="opaque password value"', "opaque password value"],
+    ["WEBHOOK_SECRET='opaque secret value'", "opaque secret value"],
+  ])("redacts the complete quoted value in %s", (assignment, secret) => {
+    const sanitized = sanitizeWedgeLogLine(
+      `gateway startup failed: ${assignment}; safe diagnostic remains`,
+    );
+
+    expect(sanitized).not.toContain(secret);
+    expect(sanitized).toContain("REDACTED");
+    expect(sanitized).toContain("; safe diagnostic remains");
+  });
+
   it("leaves ordinary wedge lines untouched", () => {
     const line =
       "gateway startup failed: listen EADDRINUSE. Process will stay alive; fix the issue and restart.";

src/lib/actions/sandbox/gateway-wedge-diagnostics.ts

@@ -18,6 +18,7 @@
 // defaulted off.
 
 import { shellQuote } from "../../runner";
+import { redactFull } from "../../security/redact";
 import type { SandboxCommandResult } from "./process-recovery";
 
 export type SandboxExec = (sandboxName: string, command: string) => SandboxCommandResult | null;
@@ -29,17 +30,25 @@ const WEDGE_LOG_SIGNATURE =
 // strip terminal control characters (no escape-sequence forgery in operator
 // terminals) and redact common credential shapes before printing.
 const CONTROL_CHARS_RE = new RegExp("[\\u0000-\\u0008\\u000b-\\u001f\\u007f-\\u009f]", "g");
-const SECRET_PATTERNS: RegExp[] = [
-  /\b(authorization\s*:\s*bearer)\s+\S+/gi,
-  /\b(api[-_]?key|token|secret|password)(["']?\s*[=:]\s*["']?)\S+/gi,
-  /\bnvapi-\S+/gi,
-];
+// These local patterns run after redactFull and stay: the `nvapi-\S+` catch-all
+// is unbounded where the shared one requires ten or more characters.
+const AUTHORIZATION_PATTERN = /\b(authorization\s*:\s*bearer)\s+\S+/gi;
+const LOCAL_SECRET_ASSIGNMENT_PATTERN =
+  /\b(api[-_]?key|token|secret|password)(["']?\s*[=:]\s*)("(?:\\.|[^"\\])*"|'(?:\\.|[^'\\])*'|\S+)/gi;
+const NVAPI_PATTERN = /\bnvapi-\S+/gi;
 
 export function sanitizeWedgeLogLine(line: string): string {
   let sanitized = line.replace(CONTROL_CHARS_RE, "");
-  sanitized = sanitized.replace(SECRET_PATTERNS[0], "$1 [REDACTED]");
-  sanitized = sanitized.replace(SECRET_PATTERNS[1], "$1$2[REDACTED]");
-  sanitized = sanitized.replace(SECRET_PATTERNS[2], "[REDACTED]");
+  sanitized = redactFull(sanitized);
+  sanitized = sanitized.replace(AUTHORIZATION_PATTERN, "$1 [REDACTED]");
+  sanitized = sanitized.replace(
+    LOCAL_SECRET_ASSIGNMENT_PATTERN,
+    (_match: string, key: string, separator: string, value: string) => {
+      const quote = value.startsWith('"') ? '"' : value.startsWith("'") ? "'" : "";
+      return `${key}${separator}${quote}[REDACTED]${quote}`;
+    },
+  );
+  sanitized = sanitized.replace(NVAPI_PATTERN, "[REDACTED]");
   return sanitized.trim();
 }
 

src/lib/security/redact.test.ts

@@ -59,6 +59,34 @@ describe("redactForLog", () => {
     expect(redactForLog(assignment)).toBe(expected);
   });
 
+  it.each([
+    [
+      'CUSTOM_API_KEY="opaque api key value" safe diagnostic',
+      'CUSTOM_API_KEY="<REDACTED>" safe diagnostic',
+    ],
+    [
+      "CUSTOM_TOKEN='opaque token value' safe diagnostic",
+      "CUSTOM_TOKEN='<REDACTED>' safe diagnostic",
+    ],
+    [
+      'CUSTOM_PASSWORD="opaque password value" safe diagnostic',
+      'CUSTOM_PASSWORD="<REDACTED>" safe diagnostic',
+    ],
+    [
+      "CUSTOM_SECRET='opaque secret value' safe diagnostic",
+      "CUSTOM_SECRET='<REDACTED>' safe diagnostic",
+    ],
+  ])("redacts the complete quoted assignment in %s", (assignment, expected) => {
+    expect(redactFull(assignment)).toBe(expected);
+    expect(redactForLog(assignment)).toBe(expected);
+  });
+
+  it("redacts a quoted multiword sensitive environment assignment before its suffix", () => {
+    expect(redactSensitiveText('OPENAI_API_KEY="opaque first second" safe diagnostic')).toBe(
+      "OPENAI_API_KEY=<REDACTED> safe diagnostic",
+    );
+  });
+
   it("preserves benign structured keys containing pass", () => {
     const benign = {
       compass: "north",

src/lib/security/redact.ts

@@ -45,8 +45,9 @@ const SENSITIVE_ENV_ASSIGNMENT_KEYS = [
   ...listMessagingCredentialMetadata().map((credential) => credential.providerEnvKey),
 ];
 
+const SENSITIVE_ENV_ASSIGNMENT_VALUE = String.raw`(?:"(?:\\.|[^"\\])*"|'(?:\\.|[^'\\])*'|\S+)`;
 const SENSITIVE_ENV_ASSIGNMENT_PATTERN = new RegExp(
-  `(${SENSITIVE_ENV_ASSIGNMENT_KEYS.map(escapeRegExp).join("|")})=\\S+`,
+  `(${SENSITIVE_ENV_ASSIGNMENT_KEYS.map(escapeRegExp).join("|")})=${SENSITIVE_ENV_ASSIGNMENT_VALUE}`,
   "gi",
 );
 
@@ -100,6 +101,19 @@ export function writeRedactedResult(
 
 // ── Full redaction (debug.ts style) ─────────────────────────────
 
+const UNDERSCORE_SECRET_ASSIGNMENT_KEY_SOURCE =
+  "(?:[A-Za-z0-9]{1,128}_(?:key|token|secret|credential|password|passwd|pass)|(?:x[-_])?api[-_]key|token|secret|credential|password|passwd|pass)";
+const CAMEL_SECRET_ASSIGNMENT_KEY_SOURCE =
+  "(?:[A-Za-z0-9]{1,128}(?:Token|Secret|Credential)|[A-Za-z0-9]{0,128}(?:[Aa]ccess|[Rr]efresh|[Cc]lient|[Bb]earer|[Aa]uth|[Aa][Pp][Ii]|[Pp]rivate|[Ss]igning|[Ss]ession|[Bb]ot|[Aa]pp|[Rr]esolved)Key|[A-Za-z0-9]{1,128}(?:Password|Passwd|Pass))";
+
+function quotedSecretAssignmentPatterns(keySource: string, flags: string): [RegExp, string][] {
+  const prefix = `((?:^|[^A-Za-z0-9])${keySource}["']?(?:[ \\t]{0,32}[=:][ \\t]{0,32}|[ \\t]{1,32}))`;
+  return [
+    [new RegExp(`${prefix}"(?:\\\\.|[^"\\\\])*"`, flags), '$1"<REDACTED>"'],
+    [new RegExp(`${prefix}'(?:\\\\.|[^'\\\\])*'`, flags), "$1'<REDACTED>'"],
+  ];
+}
+
 const FULL_REDACT_PATTERNS: [RegExp, string][] = [
   ...SECRET_BLOCK_PATTERNS.map((p): [RegExp, string] => [
     new RegExp(p.source, p.flags),
@@ -142,6 +156,9 @@ const FULL_REDACT_PATTERNS: [RegExp, string][] = [
     "$1 <REDACTED>",
   ],
   [/(\b(?:cookie|set-cookie)[ \t]*[:=][ \t]*)[^\r\n]*/gi, "$1<REDACTED>"],
+  ...quotedSecretAssignmentPatterns(UNDERSCORE_SECRET_ASSIGNMENT_KEY_SOURCE, "gi"),
+  ...quotedSecretAssignmentPatterns(CAMEL_SECRET_ASSIGNMENT_KEY_SOURCE, "g"),
+  ...quotedSecretAssignmentPatterns("KEY", "g"),
   [
     /((?:^|[^A-Za-z0-9])(?:[A-Za-z0-9]{1,128}_(?:key|token|secret|credential|password|passwd|pass)|(?:x[-_])?api[-_]key|token|secret|credential|password|passwd|pass)["']?(?:[ \t]{0,32}[=:][ \t]{0,32}|[ \t]{1,32})["']?)[^\s'"]+((?:"|')?)/gi,
     "$1<REDACTED>$2",