fix: resolve 20 Sentry issues and fix navbar test flakiness

Sentry fixes:
- Only send 5xx errors to Sentry (was sending 4xx rate-limit, media type errors)
- Encode non-ASCII chars in X-Output-Filename header (encodeURIComponent)
- Handle FK constraint failures gracefully in file upload, pipeline save, API keys
- Harden getDirSize against ENOENT race on readdirSync

Test fixes:
- Wrap navbar test renders in act() to flush async useEffect state updates
- Add useEffect cleanup to navbar to prevent state updates on unmounted component
- Fixes timeout when running in full test suite

apps/api/src/index.ts

@@ -100,7 +100,9 @@ app.setErrorHandler((error: Error & { statusCode?: number }, request, reply) =>
     { err: error, url: request.url, method: request.method },
     "Unhandled request error",
   );
-  captureException(error, request);
+  if (statusCode >= 500) {
+    captureException(error, request);
+  }
   const isProduction = process.env.NODE_ENV === "production";
   reply.status(statusCode).send({
     error: statusCode >= 500 ? "Internal server error" : error.message,

apps/api/src/routes/api-keys.ts

@@ -72,17 +72,21 @@ export async function apiKeyRoutes(app: FastifyInstance): Promise<void> {
     const keyPrefix = computeKeyPrefix(rawKey);
     const id = randomUUID();
 
-    db.insert(schema.apiKeys)
-      .values({
-        id,
-        userId: user.id,
-        keyHash,
-        keyPrefix,
-        name,
-        permissions: scopedPermissions ? JSON.stringify(scopedPermissions) : null,
-        expiresAt,
-      })
-      .run();
+    try {
+      db.insert(schema.apiKeys)
+        .values({
+          id,
+          userId: user.id,
+          keyHash,
+          keyPrefix,
+          name,
+          permissions: scopedPermissions ? JSON.stringify(scopedPermissions) : null,
+          expiresAt,
+        })
+        .run();
+    } catch {
+      return reply.status(409).send({ error: "Failed to create API key" });
+    }
 
     auditLog(request.log, "API_KEY_CREATED", { userId: user.id, keyId: id, keyName: name });
 

apps/api/src/routes/features.ts

@@ -9,7 +9,7 @@
 
 import { spawn } from "node:child_process";
 import crypto from "node:crypto";
-import { existsSync, readdirSync, readFileSync, statSync, unlinkSync } from "node:fs";
+import { type Dirent, existsSync, readdirSync, readFileSync, statSync, unlinkSync } from "node:fs";
 import { join } from "node:path";
 import { shutdownDispatcher } from "@snapotter/ai";
 import { ANALYTICS_EVENTS, FEATURE_BUNDLES } from "@snapotter/shared";
@@ -67,7 +67,12 @@ function getDirSize(dirPath: string): number {
   if (!existsSync(dirPath)) return 0;
 
   let total = 0;
-  const entries = readdirSync(dirPath, { withFileTypes: true });
+  let entries: Dirent[];
+  try {
+    entries = readdirSync(dirPath, { withFileTypes: true });
+  } catch {
+    return 0;
+  }
   for (const entry of entries) {
     const fullPath = join(dirPath, entry.name);
     if (entry.isDirectory()) {

apps/api/src/routes/pipeline.ts

@@ -329,15 +329,19 @@ export async function registerPipelineRoutes(app: FastifyInstance): Promise<void
 
     const id = randomUUID();
 
-    db.insert(schema.pipelines)
-      .values({
-        id,
-        userId: user.id,
-        name,
-        description: description ?? null,
-        steps: JSON.stringify(steps),
-      })
-      .run();
+    try {
+      db.insert(schema.pipelines)
+        .values({
+          id,
+          userId: user.id,
+          name,
+          description: description ?? null,
+          steps: JSON.stringify(steps),
+        })
+        .run();
+    } catch {
+      return reply.status(409).send({ error: "Failed to save pipeline" });
+    }
 
     return reply.status(201).send({
       id,

apps/api/src/routes/tools/optimize-for-web.ts

@@ -149,7 +149,7 @@ export function registerOptimizeForWeb(app: FastifyInstance) {
         reply.header("Content-Type", result.contentType);
         reply.header("X-Original-Size", String(fileBuffer.length));
         reply.header("X-Processed-Size", String(result.buffer.length));
-        reply.header("X-Output-Filename", result.filename);
+        reply.header("X-Output-Filename", encodeURIComponent(result.filename));
         return reply.send(result.buffer);
       } catch (err) {
         const message = err instanceof Error ? err.message : "Preview processing failed";

apps/api/src/routes/user-files.ts

@@ -198,21 +198,25 @@ export async function userFileRoutes(app: FastifyInstance): Promise<void> {
 
       // Create DB record
       const id = randomUUID();
-      db.insert(schema.userFiles)
-        .values({
-          id,
-          userId,
-          originalName: safeName,
-          storedName,
-          mimeType,
-          size: safeBuffer.length,
-          width: validation.width,
-          height: validation.height,
-          version: 1,
-          parentId: null,
-          toolChain: null,
-        })
-        .run();
+      try {
+        db.insert(schema.userFiles)
+          .values({
+            id,
+            userId,
+            originalName: safeName,
+            storedName,
+            mimeType,
+            size: safeBuffer.length,
+            width: validation.width,
+            height: validation.height,
+            version: 1,
+            parentId: null,
+            toolChain: null,
+          })
+          .run();
+      } catch {
+        return reply.status(409).send({ error: "Failed to save file record" });
+      }
 
       const row = db.select().from(schema.userFiles).where(eq(schema.userFiles.id, id)).get();
 
@@ -555,21 +559,25 @@ export async function userFileRoutes(app: FastifyInstance): Promise<void> {
 
     // Create DB record
     const id = randomUUID();
-    db.insert(schema.userFiles)
-      .values({
-        id,
-        userId,
-        originalName: resultName,
-        storedName,
-        mimeType,
-        size: safeResultBuffer.length,
-        width: validation.width,
-        height: validation.height,
-        version: nextVersion,
-        parentId,
-        toolChain: JSON.stringify(newChain),
-      })
-      .run();
+    try {
+      db.insert(schema.userFiles)
+        .values({
+          id,
+          userId,
+          originalName: resultName,
+          storedName,
+          mimeType,
+          size: safeResultBuffer.length,
+          width: validation.width,
+          height: validation.height,
+          version: nextVersion,
+          parentId,
+          toolChain: JSON.stringify(newChain),
+        })
+        .run();
+    } catch {
+      return reply.status(409).send({ error: "Failed to save result record" });
+    }
 
     const row = db.select().from(schema.userFiles).where(eq(schema.userFiles.id, id)).get();