fix(build): packed tarball boot crash — server-ws timeout import escaped the package (#7065 class)

changelog.d/fixes/pack-boot-runtimetimeouts-sibling.md

@@ -0,0 +1 @@
+- **Build**: the packed tarball boots again — #7191's `../../src/…runtimeTimeouts.ts` import in `standalone-server-ws.mjs` escaped the package after the dist-root copy (`ERR_MODULE_NOT_FOUND` on every boot, #7065 class, caught live by the new `check:pack-boot` gate); the helper now lives in the shipped sibling `main-server-timeouts.mjs` (parity-tested against the canonical TS implementation) and the closure test bans package-escaping `../` imports in npm-shipped wrappers

scripts/build/assembleStandalone.mjs

@@ -135,6 +135,11 @@ const EXTRA_MODULE_ENTRIES = [
     src: ["scripts", "dev", "peer-stamp.mjs"],
     dest: ["peer-stamp.mjs"],
   },
+  {
+    label: "main-server timeouts (server-ws.mjs dependency, #7003/#7065-class)",
+    src: ["scripts", "dev", "main-server-timeouts.mjs"],
+    dest: ["main-server-timeouts.mjs"],
+  },
   {
     label: "HTTP method guard (server-ws.mjs dependency)",
     src: ["scripts", "dev", "http-method-guard.cjs"],

scripts/build/pack-artifact-policy.ts

@@ -46,6 +46,7 @@ export const APP_STAGING_ALLOWED_EXACT_PATHS: string[] = [
   "open-sse/services/compression/engines/llmlingua/onnxWorker.js",
   "package.json",
   "peer-stamp.mjs",
+  "main-server-timeouts.mjs",
   "responses-ws-proxy.mjs",
   "scripts/dev/sync-env.mjs",
   "scripts/dev/tls-options.mjs",
@@ -152,6 +153,7 @@ export const PACK_ARTIFACT_REQUIRED_PATHS: string[] = [
   "dist/server-ws.mjs",
   "dist/responses-ws-proxy.mjs",
   "dist/peer-stamp.mjs",
+  "dist/main-server-timeouts.mjs",
   "dist/http-method-guard.cjs",
   // #5452: regression guard — make check:pack-artifact fail loudly if the TLS
   // opt-in sidecar (imported by dist/server-ws.mjs) ever vanishes from the tarball.

scripts/dev/main-server-timeouts.mjs

@@ -0,0 +1,47 @@
+// Main-server keepAlive/headers timeouts (#7003) — SIBLING module of
+// standalone-server-ws.mjs. The shipped server-ws.mjs may only import
+// siblings copied next to it by assembleStandalone (peer-stamp, tls-options,
+// the guards): a ../../src/... import resolves OUTSIDE the package after the
+// copy to the dist root and crashes boot with ERR_MODULE_NOT_FOUND (caught
+// live by check:pack-boot on 2026-07-15 — the #7065 class).
+// Parity with src/shared/utils/runtimeTimeouts.ts#getMainServerTimeoutConfig
+// is enforced by tests/unit/main-server-timeouts-parity.test.ts.
+
+export const DEFAULT_MAIN_SERVER_KEEPALIVE_TIMEOUT_MS = 65_000;
+export const DEFAULT_MAIN_SERVER_HEADERS_TIMEOUT_MS = 66_000;
+
+function readTimeoutMs(env, name, defaultValue, { allowZero = false, logger } = {}) {
+  const raw = env[name];
+  if (raw == null || raw.trim() === "") return defaultValue;
+  const parsed = Number(raw);
+  const isValid = Number.isFinite(parsed) && (allowZero ? parsed >= 0 : parsed > 0);
+  if (!isValid) {
+    logger?.(`Invalid ${name}="${raw}". Using default ${defaultValue}ms.`);
+    return defaultValue;
+  }
+  return Math.floor(parsed);
+}
+
+export function getMainServerTimeoutConfig(env = process.env, logger) {
+  const keepAliveTimeoutMs = readTimeoutMs(
+    env,
+    "MAIN_SERVER_KEEPALIVE_TIMEOUT_MS",
+    DEFAULT_MAIN_SERVER_KEEPALIVE_TIMEOUT_MS,
+    { allowZero: true, logger }
+  );
+  const headersTimeoutMs = readTimeoutMs(
+    env,
+    "MAIN_SERVER_HEADERS_TIMEOUT_MS",
+    DEFAULT_MAIN_SERVER_HEADERS_TIMEOUT_MS,
+    { allowZero: true, logger }
+  );
+  return {
+    keepAliveTimeoutMs,
+    // Node requires headersTimeout > keepAliveTimeout; keep both configurable
+    // but always coherent (mirrors the canonical TS implementation).
+    headersTimeoutMs:
+      headersTimeoutMs > 0 && keepAliveTimeoutMs > 0
+        ? Math.max(headersTimeoutMs, keepAliveTimeoutMs + 1_000)
+        : headersTimeoutMs,
+  };
+}

scripts/dev/run-next.mjs

@@ -14,7 +14,7 @@ import headResponseGuard from "./head-response-guard.cjs";
 import { ensureNativeSqlite } from "./ensure-native-sqlite.mjs";
 import { isTurbopackCacheCorruption, purgeAllTurbopackCaches } from "./turbopackCacheHeal.mjs";
 import { randomUUID } from "node:crypto";
-import { getMainServerTimeoutConfig } from "../../src/shared/utils/runtimeTimeouts.ts";
+import { getMainServerTimeoutConfig } from "./main-server-timeouts.mjs";
 
 const { maybeHandleDisallowedMethod } = methodGuard;
 const { wrapRequestListenerWithHeadResponseGuard } = headResponseGuard;

scripts/dev/standalone-server-ws.mjs

@@ -7,7 +7,7 @@ import { maybeHandleWebdav } from "./webdav-handler.mjs";
 import methodGuard from "./http-method-guard.cjs";
 import headResponseGuard from "./head-response-guard.cjs";
 import { resolveTlsOptions, createServerListener } from "./tls-options.mjs";
-import { getMainServerTimeoutConfig } from "../../src/shared/utils/runtimeTimeouts.ts";
+import { getMainServerTimeoutConfig } from "./main-server-timeouts.mjs";
 
 const originalCreateServer = http.createServer.bind(http);
 const proxiesByPort = new Map();

tests/unit/main-server-timeouts-parity.test.ts

@@ -0,0 +1,39 @@
+import test from "node:test";
+import assert from "node:assert";
+import { getMainServerTimeoutConfig as mjsImpl } from "../../scripts/dev/main-server-timeouts.mjs";
+import { getMainServerTimeoutConfig as tsImpl } from "../../src/shared/utils/runtimeTimeouts.ts";
+
+// The shipped server-ws.mjs uses the SIBLING scripts/dev/main-server-timeouts.mjs
+// (a ../../src import escapes the package after the dist copy — 2026-07-15 boot
+// crash, #7065 class). This parity matrix is the anti-drift guard between the
+// sibling and the canonical src/shared/utils/runtimeTimeouts.ts implementation.
+const ENV_MATRIX: Record<string, string | undefined>[] = [
+  {},
+  { MAIN_SERVER_KEEPALIVE_TIMEOUT_MS: "70000" },
+  { MAIN_SERVER_HEADERS_TIMEOUT_MS: "80000" },
+  { MAIN_SERVER_KEEPALIVE_TIMEOUT_MS: "90000", MAIN_SERVER_HEADERS_TIMEOUT_MS: "10000" },
+  { MAIN_SERVER_KEEPALIVE_TIMEOUT_MS: "0", MAIN_SERVER_HEADERS_TIMEOUT_MS: "0" },
+  { MAIN_SERVER_KEEPALIVE_TIMEOUT_MS: "abc" },
+  { MAIN_SERVER_KEEPALIVE_TIMEOUT_MS: "  " },
+  { MAIN_SERVER_KEEPALIVE_TIMEOUT_MS: "-5" },
+  { MAIN_SERVER_KEEPALIVE_TIMEOUT_MS: "1234.9" },
+];
+
+test("sibling main-server-timeouts.mjs stays in parity with runtimeTimeouts.ts", () => {
+  for (const env of ENV_MATRIX) {
+    assert.deepStrictEqual(
+      mjsImpl(env),
+      tsImpl(env),
+      `divergence for env ${JSON.stringify(env)}`
+    );
+  }
+});
+
+test("invalid values log through the provided logger in both implementations", () => {
+  const logsA: string[] = [];
+  const logsB: string[] = [];
+  mjsImpl({ MAIN_SERVER_KEEPALIVE_TIMEOUT_MS: "bogus" }, (m) => logsA.push(m));
+  tsImpl({ MAIN_SERVER_KEEPALIVE_TIMEOUT_MS: "bogus" }, (m) => logsB.push(m));
+  assert.strictEqual(logsA.length, 1);
+  assert.deepStrictEqual(logsA, logsB);
+});

tests/unit/pack-artifact-entrypoint-closures.test.ts

@@ -56,6 +56,16 @@ function localImports(filePath: string): string[] {
   return [...new Set(patterns.flatMap((re) => [...src.matchAll(re)].map((m) => m[1])))];
 }
 
+/** Parent-relative specifiers (../) in a wrapper file — ALWAYS a packaging bug. */
+export function parentRelativeImports(src: string): string[] {
+  const patterns = [
+    /from\s+["'](\.\.\/[^"']+)["']/g,
+    /import\(\s*["'](\.\.\/[^"']+)["']\s*\)/g,
+    /require\(\s*["'](\.\.\/[^"']+)["']\s*\)/g,
+  ];
+  return [...new Set(patterns.flatMap((re) => [...src.matchAll(re)].map((m) => m[1])))];
+}
+
 // Wrappers that ship in the npm channel are exactly those whose dest survives the prune.
 // Wrappers intentionally outside the npm tarball (e.g. healthcheck.mjs, Docker-only) are
 // excluded: their imports live or die with them, consistently.
@@ -123,3 +133,20 @@ test("every bin/omniroute.mjs local import is enforced by check:pack-artifact",
     `add bin/<file> to PACK_ARTIFACT_REQUIRED_PATHS: ${missing.join(", ")}`
   );
 });
+
+test("no npm-shipped wrapper uses a parent-relative (../) import — it escapes the package after the dist-root copy", () => {
+  // 2026-07-15 live incident: standalone-server-ws.mjs imported
+  // ../../src/shared/utils/runtimeTimeouts.ts (merged in #7191); copied to the dist
+  // root, the specifier resolved to node_modules/src/... OUTSIDE the package and
+  // every boot of the packed tarball crashed with ERR_MODULE_NOT_FOUND (#7065
+  // class — caught by check:pack-boot). Wrapper dependencies must be SIBLINGS
+  // (./x.mjs) with their own EXTRA_MODULE_ENTRIES copy + pack allowlist entry.
+  for (const wrapper of npmShippedWrappers()) {
+    const escaping = parentRelativeImports(fs.readFileSync(path.join(ROOT, wrapper.src), "utf8"));
+    assert.deepEqual(
+      escaping,
+      [],
+      `${wrapper.src} has package-escaping imports: ${escaping.join(", ")} — extract to a sibling module instead`
+    );
+  }
+});

tests/unit/pack-artifact-policy.test.ts

@@ -112,6 +112,7 @@ test("findMissingArtifactPaths flags missing root runtime files in the tarball",
     "bin/nodeRuntimeSupport.mjs",
     "dist/head-response-guard.cjs",
     "dist/http-method-guard.cjs",
+    "dist/main-server-timeouts.mjs",
     "dist/open-sse/services/compression/engines/rtk/filters/generic-output.json",
     "dist/open-sse/services/compression/rules/en/filler.json",
     "dist/peer-stamp.mjs",

tests/unit/standalone-server-ws-keepalive-timeout-7003.test.ts

@@ -33,11 +33,15 @@ const source = fs.readFileSync(
 );
 
 test("standalone-server-ws.mjs imports getMainServerTimeoutConfig", () => {
+  // The wrapper must import the SIBLING ./main-server-timeouts.mjs — a
+  // ../../src/... import escapes the package after the dist-root copy and
+  // crashed every packed boot (2026-07-15, #7065 class). Parity with the
+  // canonical runtimeTimeouts.ts is guarded by main-server-timeouts-parity.test.ts.
   assert.match(
     source,
-    /import\s*\{\s*getMainServerTimeoutConfig\s*\}\s*from\s*["'][^"']*runtimeTimeouts(?:\.ts)?["']/,
-    "expected the production server wrapper to import getMainServerTimeoutConfig, " +
-      "the same helper run-next.mjs uses"
+    /import\s*\{\s*getMainServerTimeoutConfig\s*\}\s*from\s*["']\.\/main-server-timeouts\.mjs["']/,
+    "expected the production server wrapper to import getMainServerTimeoutConfig " +
+      "from its shipped sibling module (./main-server-timeouts.mjs)"
   );
 });