chore(desktop): remove Claude binary from build pipeline

[Kitenite]

Summary

• Stop downloading and bundling the Claude Code binary during build/package steps
• The SDK resolves the Claude binary at runtime, so bundling is unnecessary
• Chat is now tolerant to a missing binary — won't crash, just lets the SDK handle resolution

Changes

• apps/desktop/package.json: Removed download:claude from prebuild and prepackage hooks
• apps/desktop/electron-builder.ts: Commented out the Claude binary extraResources entry
• apps/desktop/.../agent-execution.ts: getClaudeBinaryPath() returns null when binary doesn't exist; pathToClaudeCodeExecutable is omitted so the SDK resolves it on its own
• bun.lock: Version bump reflected

Test Plan

• bun run typecheck passes in apps/desktop
• bun run build in apps/desktop succeeds without downloading the Claude binary
• AI chat works when Claude Code is installed globally (SDK resolves it)
• AI chat surfaces a graceful error when Claude Code is not installed at all (no crash)

Summary by CodeRabbit

• Refactor
  • Updated binary resolution to occur at runtime instead of during the build process, simplifying the build workflow and enabling more flexible deployment scenarios.
  • Removed pre-download steps from build scripts for improved build efficiency.
  • Enhanced error handling for cases where the binary may not be available at runtime.

[coderabbitai]

📝 Walkthrough

Walkthrough

These changes shift Claude binary handling from build-time bundling to runtime resolution. The electron-builder configuration no longer bundles the platform-specific binary, the build scripts no longer download it, and runtime code now validates binary existence before use.

Changes

Cohort / File(s)	Summary
Build Configuration apps/desktop/electron-builder.ts, apps/desktop/package.json	Removed build-time binary bundling: commented out extraResources entry that packaged Claude Code binary, and removed download:claude step from prebuild and prepackage scripts.
Runtime Resolution apps/desktop/src/lib/trpc/routers/ai-chat/utils/session-manager/agent-execution.ts	Added nullable getClaudeBinaryPath() function that validates binary existence at runtime with existsSync, returning null if missing; conditional spread ensures pathToClaudeCodeExecutable is only passed when binary is available.

Estimated code review effort

🎯 2 (Simple) | ⏱️ ~10 minutes

Possibly related PRs

• refactor(desktop): rewrite session manager as thin HTTP proxy orchestrator #1258: Removes binary-path resolution and Claude SDK usage from session manager—directly modifies same Claude binary handling logic in agent-execution.
• Update finding Claude #444: Improves runtime "find Claude" utilities for path discovery and validation—complementary to the runtime checks now needed after removing build-time bundling.
• Fix claude settings hooks + refactor agents-setup #439: Refactors agent-setup to create wrappers and locate Claude binary at runtime—related to the new runtime resolution approach.

Poem

🐰 No more binaries packed in the build so tight,
Runtime shall find them—or gracefully yield null's light!
From bundle to fetch, we hop with delight,
Existence checked thrice, keeping all systems right! ✨

🚥 Pre-merge checks | ✅ 3 | ❌ 1

❌ Failed checks (1 warning)

Check name	Status	Explanation	Resolution
Docstring Coverage	⚠️ Warning	Docstring coverage is 0.00% which is insufficient. The required threshold is 80.00%.	Write docstrings for the functions missing them to satisfy the coverage threshold.

✅ Passed checks (3 passed)

Check name	Status	Explanation
Title check	✅ Passed	The title clearly and concisely summarizes the main change: removing the Claude binary from the build pipeline, which is the primary objective of this pull request.
Description check	✅ Passed	The PR description covers the key sections from the template including Summary, Changes, and Test Plan, providing clear context about what was changed and why.
Merge Conflict Detection	✅ Passed	✅ No merge conflicts detected when merging into main

_{✏️ Tip: You can configure your own custom pre-merge checks in the settings.}

✨ Finishing touches

• 📝 Generate docstrings

🧪 Generate unit tests (beta)

• Create PR with unit tests
• Post copyable unit tests in a comment
• Commit unit tests in branch kitenite/remove-binary-from-build

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No actionable comments were generated in the recent review. 🎉

🧹 Recent nitpick comments

apps/desktop/electron-builder.ts (1)

59-65: Remove the commented-out block instead of leaving dead config.

Commented-out code adds noise. If this needs to be restored, it's recoverable from git history. Consider removing it entirely or replacing with just the comment on line 59.

♻️ Suggested diff

-		// Claude Code binary - no longer bundled; the SDK resolves it at runtime
-		// {
-		// 	// biome-ignore lint/suspicious/noTemplateCurlyInString: electron-builder variable interpolation
-		// 	from: "resources/bin/${platform}-${arch}",
-		// 	to: "bin",
-		// 	filter: ["**/*"],
-		// },

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[github-actions]

🧹 Preview Cleanup Complete

The following preview resources have been cleaned up:

• ✅ Neon database branch
• ✅ Electric Fly.io app
• ✅ Streams Fly.io app

Thank you for your contribution! 🎉