fix: improve handling of StandaloneModuleGraph initialization

src/bun.js.zig

@@ -18,9 +18,14 @@ pub const Run = struct {
         bun.jsc.initialize(false);
         bun.analytics.Features.standalone_executable += 1;
 
-        const graph_ptr = try bun.default_allocator.create(bun.StandaloneModuleGraph);
-        graph_ptr.* = graph;
-        graph_ptr.set();
+        // Use existing graph if already set (set early in cli.zig for execArgv case),
+        // otherwise create and set it now
+        const graph_ptr = bun.StandaloneModuleGraph.get() orelse blk: {
+            const ptr = try bun.default_allocator.create(bun.StandaloneModuleGraph);
+            ptr.* = graph;
+            ptr.set();
+            break :blk ptr;
+        };
 
         js_ast.Expr.Data.Store.create();
         js_ast.Stmt.Data.Store.create();

src/cli.zig

@@ -683,6 +683,12 @@ pub const Command = struct {
             if (try bun.StandaloneModuleGraph.fromExecutable(bun.default_allocator)) |graph| {
                 var offset_for_passthrough: usize = 0;
 
+                // Set the graph globally early so loadConfig can check compile flags
+                // (e.g., disable_autoload_bunfig) before Command.init loads config
+                const graph_ptr = try bun.default_allocator.create(bun.StandaloneModuleGraph);
+                graph_ptr.* = graph;
+                graph_ptr.set();
+
                 const ctx: *ContextData = brk: {
                     if (graph.compile_exec_argv.len > 0) {
                         const original_argv_len = bun.argv.len;

src/cli/Arguments.zig

@@ -295,6 +295,13 @@ fn getHomeConfigPath(buf: *bun.PathBuffer) ?[:0]const u8 {
     return null;
 }
 pub fn loadConfig(allocator: std.mem.Allocator, user_config_path_: ?string, ctx: Command.Context, comptime cmd: Command.Tag) OOM!void {
+    // For standalone executables, respect compile-time flag to disable bunfig autoloading
+    if (bun.StandaloneModuleGraph.get()) |graph| {
+        if (graph.flags.disable_autoload_bunfig) {
+            return;
+        }
+    }
+
     var config_buf: bun.PathBuffer = undefined;
     if (comptime cmd.readGlobalConfig()) {
         if (!ctx.has_loaded_global_config) {

test/bundler/bundler_compile_autoload.test.ts

@@ -213,6 +213,59 @@ console.log("PRELOAD");
     },
   });
 
+  // Test that autoloadBunfig: false is respected when execArgv is set
+  // Regression test: execArgv was causing bunfig.toml to be loaded even when disabled
+  itBundled("compile/AutoloadBunfigDisabledWithExecArgv", {
+    compile: {
+      autoloadBunfig: false,
+      execArgv: ["--smol"],
+    },
+    files: {
+      "/entry.ts": /* js */ `
+        console.log("ENTRY");
+      `,
+    },
+    runtimeFiles: {
+      "/bunfig.toml": `
+preload = ["./preload.ts"]
+      `,
+      "/preload.ts": `
+console.log("PRELOAD");
+      `,
+    },
+    run: {
+      // When bunfig is disabled, preload should NOT execute even with execArgv
+      stdout: "ENTRY",
+      setCwd: true,
+    },
+  });
+
+  // Test CLI backend: autoloadBunfig: false with execArgv
+  itBundled("compile/AutoloadBunfigDisabledWithExecArgvCLI", {
+    compile: {
+      autoloadBunfig: false,
+      execArgv: ["--smol"],
+    },
+    backend: "cli",
+    files: {
+      "/entry.ts": /* js */ `
+        console.log("ENTRY");
+      `,
+    },
+    runtimeFiles: {
+      "/bunfig.toml": `
+preload = ["./preload.ts"]
+      `,
+      "/preload.ts": `
+console.log("PRELOAD");
+      `,
+    },
+    run: {
+      stdout: "ENTRY",
+      setCwd: true,
+    },
+  });
+
   // Test CLI backend with autoloadBunfig: true
   itBundled("compile/AutoloadBunfigEnabledCLI", {
     compile: {