fix(startup): honor documented env loading

electron/main.js

@@ -64,6 +64,64 @@ let serverPort = 20128;
 
 const getServerUrl = () => `http://localhost:${serverPort}`;
 
+function resolveDataDir(overridePath, env = process.env) {
+  if (overridePath && overridePath.trim()) return path.resolve(overridePath);
+
+  const configured = env.DATA_DIR?.trim();
+  if (configured) return path.resolve(configured);
+
+  if (process.platform === "win32") {
+    const appData = env.APPDATA || path.join(require("os").homedir(), "AppData", "Roaming");
+    return path.join(appData, "omniroute");
+  }
+
+  const xdg = env.XDG_CONFIG_HOME?.trim();
+  if (xdg) return path.join(path.resolve(xdg), "omniroute");
+
+  return path.join(require("os").homedir(), ".omniroute");
+}
+
+function getPreferredEnvFilePath(env = process.env) {
+  const candidates = [];
+
+  if (env.DATA_DIR?.trim()) {
+    candidates.push(path.join(path.resolve(env.DATA_DIR.trim()), ".env"));
+  }
+
+  candidates.push(path.join(resolveDataDir(), ".env"));
+  candidates.push(path.join(process.cwd(), ".env"));
+
+  return candidates.find((filePath) => fs.existsSync(filePath)) || null;
+}
+
+function hasEncryptedCredentials(dbPath) {
+  if (!fs.existsSync(dbPath)) return false;
+
+  try {
+    const Database = require("better-sqlite3");
+    const db = new Database(dbPath, { readonly: true, fileMustExist: true });
+    try {
+      const row = db
+        .prepare(
+          `SELECT 1
+             FROM provider_connections
+            WHERE access_token LIKE 'enc:v1:%'
+               OR refresh_token LIKE 'enc:v1:%'
+               OR api_key LIKE 'enc:v1:%'
+               OR id_token LIKE 'enc:v1:%'
+            LIMIT 1`
+        )
+        .get();
+      return !!row;
+    } finally {
+      db.close();
+    }
+  } catch (error) {
+    const message = error instanceof Error ? error.message : String(error);
+    throw new Error(`Unable to inspect existing database at ${dbPath}: ${message}`);
+  }
+}
+
 // ── Auto-Updater Configuration ──────────────────────────────
 autoUpdater.autoDownload = false;
 autoUpdater.autoInstallOnAppQuit = true;
@@ -386,12 +444,10 @@ function startNextServer() {
   // ── Zero-config bootstrap: auto-generate required secrets ─────────────────
   // Electron uses CJS — cannot dynamically import ESM bootstrap-env.mjs.
   // This mirrors bootstrap-env.mjs logic synchronously:
-  //   1. Read persisted secrets from userData/server.env
+  //   1. Read persisted secrets from the resolved DATA_DIR/server.env
   //   2. Generate missing secrets with crypto.randomBytes()
-  //   3. Persist back to userData/server.env for future restarts
+  //   3. Persist back to DATA_DIR/server.env for future restarts
   const crypto = require("crypto");
-  const userDataDir = app.getPath("userData");
-  const serverEnvPath = path.join(userDataDir, "server.env");
 
   // Parse a simple KEY=VALUE file
   function parseEnvFile(filePath) {
@@ -407,8 +463,12 @@ function startNextServer() {
     return env;
   }
 
+  const preferredEnvPath = getPreferredEnvFilePath(process.env);
+  const preferredEnv = preferredEnvPath ? parseEnvFile(preferredEnvPath) : {};
+  const dataDir = resolveDataDir(null, { ...preferredEnv, ...process.env });
+  const serverEnvPath = path.join(dataDir, "server.env");
   const persisted = parseEnvFile(serverEnvPath);
-  const serverEnv = { ...process.env, ...persisted };
+  const serverEnv = { ...persisted, ...preferredEnv, ...process.env };
   let changed = false;
 
   if (!serverEnv.JWT_SECRET) {
@@ -417,6 +477,16 @@ function startNextServer() {
     console.log("[Electron] ✨ JWT_SECRET auto-generated");
   }
   if (!serverEnv.STORAGE_ENCRYPTION_KEY) {
+    if (hasEncryptedCredentials(path.join(dataDir, "storage.sqlite"))) {
+      console.error(
+        `[Electron] Refusing to auto-generate STORAGE_ENCRYPTION_KEY: encrypted credentials already exist in ${path.join(
+          dataDir,
+          "storage.sqlite"
+        )}. Restore the key via ${preferredEnvPath || "an appropriate .env file"}, ${serverEnvPath}, or process.env.`
+      );
+      sendToRenderer("server-status", { status: "error", port: serverPort });
+      return;
+    }
     serverEnv.STORAGE_ENCRYPTION_KEY = persisted.STORAGE_ENCRYPTION_KEY = crypto
       .randomBytes(32)
       .toString("hex");
@@ -432,7 +502,7 @@ function startNextServer() {
   if (changed) {
     serverEnv.OMNIROUTE_BOOTSTRAPPED = "true";
     try {
-      fs.mkdirSync(userDataDir, { recursive: true });
+      fs.mkdirSync(dataDir, { recursive: true });
       const lines = [
         "# Auto-generated by OmniRoute bootstrap",
         "",
@@ -454,6 +524,7 @@ function startNextServer() {
     cwd: NEXT_SERVER_PATH,
     env: {
       ...serverEnv,
+      DATA_DIR: dataDir,
       PORT: String(serverPort),
       NODE_ENV: "production",
     },

scripts/bootstrap-env.mjs

@@ -7,22 +7,25 @@
  * restarts, Docker volume remounts, and upgrades.
  *
  * Works across all deployment modes:
- *   - npm / CLI:  called from run-standalone.mjs and run-next.mjs
+ *   - npm / app runners:  called from run-standalone.mjs and run-next.mjs
  *   - Docker:     same, secrets persisted in mounted volume
- *   - Electron:   called from main.js startup, persisted in userData
+ *   - Electron:   called from main.js startup, persisted in DATA_DIR
  *
  * Priority (lowest → highest):
  *   1. Auto-generated defaults
  *   2. {DATA_DIR}/server.env  (persisted on first boot)
- *   3. .env in CWD            (user overrides)
+ *   3. Preferred config .env  (DATA_DIR/.env -> ~/.omniroute/.env -> ./.env)
  *   4. process.env            (shell / Docker -e flags, highest priority)
  */
 
-import { createHash, randomBytes } from "node:crypto";
+import { randomBytes } from "node:crypto";
 import { existsSync, mkdirSync, readFileSync, writeFileSync } from "node:fs";
+import { createRequire } from "node:module";
 import { homedir } from "node:os";
 import { join, resolve } from "node:path";
 
+const require = createRequire(import.meta.url);
+
 // ── OAuth secrets that are optional but warn if missing ─────────────────────
 const OPTIONAL_OAUTH_SECRETS = [
   { key: "ANTIGRAVITY_OAUTH_CLIENT_SECRET", label: "Antigravity OAuth" },
@@ -31,23 +34,65 @@ const OPTIONAL_OAUTH_SECRETS = [
 ];
 
 // ── Resolve DATA_DIR (mirrors dataPaths.ts logic) ───────────────────────────
-function resolveDataDir(overridePath) {
-  if (overridePath) return resolve(overridePath);
+function resolveDataDir(overridePath, env = process.env) {
+  if (overridePath?.trim()) return resolve(overridePath);
 
-  const configured = process.env.DATA_DIR?.trim();
+  const configured = env.DATA_DIR?.trim();
   if (configured) return resolve(configured);
 
   if (process.platform === "win32") {
-    const appData = process.env.APPDATA || join(homedir(), "AppData", "Roaming");
+    const appData = env.APPDATA || join(homedir(), "AppData", "Roaming");
     return join(appData, "omniroute");
   }
 
-  const xdg = process.env.XDG_CONFIG_HOME?.trim();
+  const xdg = env.XDG_CONFIG_HOME?.trim();
   if (xdg) return join(resolve(xdg), "omniroute");
 
   return join(homedir(), ".omniroute");
 }
 
+function getPreferredEnvFilePath(env = process.env) {
+  const candidates = [];
+
+  if (env.DATA_DIR?.trim()) {
+    candidates.push(join(resolve(env.DATA_DIR.trim()), ".env"));
+  }
+
+  candidates.push(join(resolveDataDir(), ".env"));
+  candidates.push(join(process.cwd(), ".env"));
+
+  return candidates.find((filePath) => existsSync(filePath)) ?? null;
+}
+
+function hasEncryptedCredentials(dataDir) {
+  const dbPath = join(dataDir, "storage.sqlite");
+  if (!existsSync(dbPath)) return false;
+
+  try {
+    const Database = require("better-sqlite3");
+    const db = new Database(dbPath, { readonly: true, fileMustExist: true });
+    try {
+      const row = db
+        .prepare(
+          `SELECT 1
+             FROM provider_connections
+            WHERE access_token LIKE 'enc:v1:%'
+               OR refresh_token LIKE 'enc:v1:%'
+               OR api_key LIKE 'enc:v1:%'
+               OR id_token LIKE 'enc:v1:%'
+            LIMIT 1`
+        )
+        .get();
+      return !!row;
+    } finally {
+      db.close();
+    }
+  } catch (error) {
+    const message = error instanceof Error ? error.message : String(error);
+    throw new Error(`Unable to inspect existing database at ${dbPath}: ${message}`);
+  }
+}
+
 // ── Parse a simple KEY=VALUE env file ───────────────────────────────────────
 function parseEnvFile(filePath) {
   if (!existsSync(filePath)) return {};
@@ -85,18 +130,17 @@ function writeEnvFile(filePath, env) {
 export function bootstrapEnv({ dataDirOverride, quiet = false } = {}) {
   const log = quiet ? () => {} : (msg) => process.stderr.write(`[bootstrap] ${msg}\n`);
 
-  const dataDir = resolveDataDir(dataDirOverride);
+  const preferredEnvPath = getPreferredEnvFilePath(process.env);
+  const preferredEnv = preferredEnvPath ? parseEnvFile(preferredEnvPath) : {};
+  const dataDir = resolveDataDir(dataDirOverride, { ...preferredEnv, ...process.env });
   const serverEnvPath = join(dataDir, "server.env");
-  const dotEnvPath = join(process.cwd(), ".env");
 
   // ── Layer 1: Load persisted server.env ────────────────────────────────────
   let persisted = parseEnvFile(serverEnvPath);
 
-  // ── Layer 2: Load .env from CWD (user overrides, higher priority) ─────────
-  const dotEnv = parseEnvFile(dotEnvPath);
-
-  // ── Merge: persisted < .env < process.env ─────────────────────────────────
-  const merged = { ...persisted, ...dotEnv, ...process.env };
+  // ── Layer 2: Load the same preferred .env that the CLI wrapper uses ───────
+  // This keeps run-next / run-standalone consistent with `bin/omniroute.mjs`.
+  const merged = { ...persisted, ...preferredEnv, ...process.env };
 
   // ── Auto-generate required secrets ────────────────────────────────────────
   let needsPersist = false;
@@ -109,6 +153,14 @@ export function bootstrapEnv({ dataDirOverride, quiet = false } = {}) {
   }
 
   if (!merged.STORAGE_ENCRYPTION_KEY?.trim()) {
+    if (hasEncryptedCredentials(dataDir)) {
+      throw new Error(
+        `Refusing to auto-generate STORAGE_ENCRYPTION_KEY: encrypted credentials already exist in ${join(
+          dataDir,
+          "storage.sqlite"
+        )}. Restore the key via ${preferredEnvPath ?? "an appropriate .env file"}, ${serverEnvPath}, or process.env.`
+      );
+    }
     persisted.STORAGE_ENCRYPTION_KEY = randomBytes(32).toString("hex");
     merged.STORAGE_ENCRYPTION_KEY = persisted.STORAGE_ENCRYPTION_KEY;
     needsPersist = true;

tests/unit/bootstrap-env.test.mjs

@@ -0,0 +1,113 @@
+import test from "node:test";
+import assert from "node:assert/strict";
+import fs from "node:fs";
+import os from "node:os";
+import path from "node:path";
+import Database from "better-sqlite3";
+
+import { bootstrapEnv } from "../../scripts/bootstrap-env.mjs";
+
+function withTempEnv(fn) {
+  const originalCwd = process.cwd();
+  const originalEnv = { ...process.env };
+  const tempRoot = fs.mkdtempSync(path.join(os.tmpdir(), "omniroute-bootstrap-test-"));
+  const tempCwd = path.join(tempRoot, "cwd");
+  const tempHome = path.join(tempRoot, "home");
+
+  fs.mkdirSync(tempCwd, { recursive: true });
+  fs.mkdirSync(tempHome, { recursive: true });
+
+  delete process.env.DATA_DIR;
+  delete process.env.XDG_CONFIG_HOME;
+  delete process.env.APPDATA;
+  delete process.env.JWT_SECRET;
+  delete process.env.STORAGE_ENCRYPTION_KEY;
+  delete process.env.STORAGE_ENCRYPTION_KEY_VERSION;
+  delete process.env.API_KEY_SECRET;
+  delete process.env.INITIAL_PASSWORD;
+  process.env.HOME = tempHome;
+  process.chdir(tempCwd);
+
+  try {
+    fn({ tempRoot, tempCwd, tempHome, dataDir: path.join(tempHome, ".omniroute") });
+  } finally {
+    process.chdir(originalCwd);
+    for (const key of Object.keys(process.env)) {
+      if (!(key in originalEnv)) delete process.env[key];
+    }
+    for (const [key, value] of Object.entries(originalEnv)) {
+      process.env[key] = value;
+    }
+    fs.rmSync(tempRoot, { recursive: true, force: true });
+  }
+}
+
+test("bootstrapEnv prefers ~/.omniroute/.env over server.env", () => {
+  withTempEnv(({ dataDir }) => {
+    fs.mkdirSync(dataDir, { recursive: true });
+    fs.writeFileSync(
+      path.join(dataDir, ".env"),
+      "STORAGE_ENCRYPTION_KEY=from-dot-env\nJWT_SECRET=jwt-from-dot-env\n",
+      "utf8"
+    );
+    fs.writeFileSync(
+      path.join(dataDir, "server.env"),
+      "STORAGE_ENCRYPTION_KEY=from-server-env\nJWT_SECRET=jwt-from-server-env\n",
+      "utf8"
+    );
+
+    const env = bootstrapEnv({ quiet: true });
+
+    assert.equal(env.STORAGE_ENCRYPTION_KEY, "from-dot-env");
+    assert.equal(env.JWT_SECRET, "jwt-from-dot-env");
+  });
+});
+
+test("bootstrapEnv refuses to generate a new key over encrypted data", () => {
+  withTempEnv(({ dataDir }) => {
+    fs.mkdirSync(dataDir, { recursive: true });
+    const db = new Database(path.join(dataDir, "storage.sqlite"));
+    try {
+      db.exec(`
+        CREATE TABLE provider_connections (
+          id TEXT PRIMARY KEY,
+          access_token TEXT,
+          refresh_token TEXT,
+          api_key TEXT,
+          id_token TEXT
+        );
+      `);
+      db.prepare("INSERT INTO provider_connections (id, access_token) VALUES (?, ?)")
+        .run("conn-1", "enc:v1:deadbeef:feedface:cafebabe");
+    } finally {
+      db.close();
+    }
+
+    assert.throws(
+      () => bootstrapEnv({ quiet: true }),
+      /Refusing to auto-generate STORAGE_ENCRYPTION_KEY/
+    );
+  });
+});
+
+test("bootstrapEnv fails closed when existing database cannot be inspected", () => {
+  withTempEnv(({ dataDir }) => {
+    fs.mkdirSync(path.join(dataDir, "storage.sqlite"), { recursive: true });
+
+    assert.throws(
+      () => bootstrapEnv({ quiet: true }),
+      /Unable to inspect existing database/
+    );
+  });
+});
+
+test("bootstrapEnv ignores blank dataDirOverride values", () => {
+  withTempEnv(({ dataDir }) => {
+    fs.mkdirSync(dataDir, { recursive: true });
+    fs.writeFileSync(path.join(dataDir, ".env"), "JWT_SECRET=jwt-from-dot-env\n", "utf8");
+
+    const env = bootstrapEnv({ dataDirOverride: "   ", quiet: true });
+
+    assert.equal(env.JWT_SECRET, "jwt-from-dot-env");
+  });
+});