From 7d9b7ec2e2504a3cf7f15ee81f0ebd88d449729c Mon Sep 17 00:00:00 2001
From: Satya Patel <satyapatel111@gmail.com>
Date: Wed, 13 May 2026 22:57:34 -0700
Subject: [PATCH] harden(host-service): connect-phase deadline +
 reconnect-guaranteed onclose
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Two stuck-state paths besides the one we already fixed:
- getAuthToken() can hang indefinitely (no upstream timeout) → connecting
  stays true → all future connect() calls early-return forever
- WebSocket can stall in CONNECTING (captive portal, NAT rebind mid-
  handshake) → onopen/onclose/onerror never fire → same wedge

A 20s connect-phase deadline collapses both into one mechanism. On
timeout we force-close any in-flight socket, reset state, and schedule
reconnect. Stale onclose for the abandoned socket no-ops via the
existing this.socket-identity check.

Also wraps onclose body in try/finally so any future throw inside it
still routes through scheduleReconnect — defense-in-depth against the
class of bug we just fixed (1001-close throwing inside cleanupChannels).
---
 .../host-service/src/tunnel/tunnel-client.ts  | 55 ++++++++++++++-----
 1 file changed, 40 insertions(+), 15 deletions(-)

diff --git a/packages/host-service/src/tunnel/tunnel-client.ts b/packages/host-service/src/tunnel/tunnel-client.ts
index 22e39cadad2..06176f16d87 100644
--- a/packages/host-service/src/tunnel/tunnel-client.ts
+++ b/packages/host-service/src/tunnel/tunnel-client.ts
@@ -11,6 +11,7 @@ const RECONNECT_BASE_MS = 1_000;
 const RECONNECT_MAX_MS = 30_000;
 const INBOUND_SILENCE_TIMEOUT_MS = 75_000;
 const WATCHDOG_INTERVAL_MS = 10_000;
+const CONNECT_TIMEOUT_MS = 20_000;
 
 export interface TunnelClientOptions {
 	relayUrl: string;
@@ -59,15 +60,32 @@ export class TunnelClient {
 		}
 		this.connecting = true;
 
+		let timedOut = false;
+		const deadline = setTimeout(() => {
+			if (this.closed) return;
+			timedOut = true;
+			console.warn(
+				`[host-service:tunnel] connect did not complete within ${CONNECT_TIMEOUT_MS}ms, forcing retry`,
+			);
+			try {
+				this.socket?.close(4001, "Connect timeout");
+			} catch {}
+			this.socket = null;
+			this.connecting = false;
+			this.scheduleReconnect();
+		}, CONNECT_TIMEOUT_MS);
+
 		// An unhandled rejection here (e.g. DNS failure inside getAuthToken on
 		// wake from sleep) crashes host-service and orphans every PTY.
 		try {
 			const token = await this.getAuthToken();
-			if (this.closed) {
-				this.connecting = false;
+			if (timedOut || this.closed) {
+				clearTimeout(deadline);
+				if (this.closed) this.connecting = false;
 				return;
 			}
 			if (!token) {
+				clearTimeout(deadline);
 				console.warn("[host-service:tunnel] no auth token available, retrying");
 				this.connecting = false;
 				this.scheduleReconnect();
@@ -84,6 +102,7 @@ export class TunnelClient {
 			this.lastInboundAt = Date.now();
 
 			socket.onopen = () => {
+				clearTimeout(deadline);
 				this.reconnectAttempts = 0;
 				this.connecting = false;
 				this.lastInboundAt = Date.now();
@@ -99,28 +118,34 @@ export class TunnelClient {
 			};
 
 			socket.onclose = (event) => {
-				const wasOurSocket = this.socket === socket;
-				if (!wasOurSocket) return;
-
-				this.socket = null;
-				this.connecting = false;
-				this.stopWatchdog();
-				this.cleanupChannels();
-
-				if (this.closed) return;
-
-				if (event.code === 1008) {
+				if (this.socket !== socket) return;
+				clearTimeout(deadline);
+				try {
+					this.socket = null;
+					this.connecting = false;
+					this.stopWatchdog();
+					this.cleanupChannels();
+					if (event.code === 1008) {
+						console.warn(
+							`[host-service:tunnel] relay rejected connection (code=${event.code}, reason=${event.reason ?? ""}); retrying`,
+						);
+					}
+				} catch (err) {
 					console.warn(
-						`[host-service:tunnel] relay rejected connection (code=${event.code}, reason=${event.reason ?? ""}); retrying`,
+						"[host-service:tunnel] error during onclose cleanup",
+						err,
 					);
+				} finally {
+					if (!this.closed) this.scheduleReconnect();
 				}
-				this.scheduleReconnect();
 			};
 
 			socket.onerror = (event) => {
 				console.error("[host-service:tunnel] socket error:", event);
 			};
 		} catch (error) {
+			clearTimeout(deadline);
+			if (timedOut) return;
 			const message = error instanceof Error ? error.message : String(error);
 			console.error(`[host-service:tunnel] connect failed: ${message}`);
 			this.socket = null;