fix: resolve 18 QA-discovered bugs across tools, previews, and the AI pipeline (#242)

Exhaustive QA sweep of all 157 tools. Fixes: CSP blob media, csv-excel ExcelJS interop, ocr-pdf segfault, chart-maker upload, non-PDF doc preview, RAW decode, merge-tool multi-file path, html-to-image chromium, ogv/wma/amr/ac3 preview fallbacks, meme/gif/stabilize codecs, nav+home a11y. Plus orphan-format and test-debt cleanup, the AI bundle build script, and a reusable Playwright QA harness under tests/qa/.

tests/qa/verify-ai.mts

@@ -0,0 +1,138 @@
+// Verifies the installed AI models produce CORRECT output (not just run), using
+// real-content fixtures. Run: ./apps/api/node_modules/.bin/tsx tests/qa/verify-ai.mts
+import { execFileSync } from "node:child_process";
+import fs from "node:fs";
+import path from "node:path";
+
+const BASE = "http://localhost:13499";
+
+async function pollSSE(jobId: string, timeoutMs = 240_000): Promise<Record<string, unknown>> {
+  const res = await fetch(`${BASE}/api/v1/jobs/${jobId}/progress`);
+  if (!res.body) return { error: "no body" };
+  const reader = res.body.getReader();
+  const dec = new TextDecoder();
+  let buf = "";
+  const deadline = Date.now() + timeoutMs;
+  while (Date.now() < deadline) {
+    const { value, done } = await reader.read();
+    if (done) break;
+    buf += dec.decode(value, { stream: true });
+    let idx: number;
+    // biome-ignore lint/suspicious/noAssignInExpressions: stream parse
+    while ((idx = buf.indexOf("\n")) >= 0) {
+      const line = buf.slice(0, idx).trim();
+      buf = buf.slice(idx + 1);
+      if (!line.startsWith("data:")) continue;
+      try {
+        const d = JSON.parse(line.slice(5).trim());
+        if (d.phase === "complete" || d.status === "completed") {
+          await reader.cancel();
+          return d;
+        }
+        if (d.phase === "failed" || d.status === "failed") {
+          await reader.cancel();
+          return { failed: true, ...d };
+        }
+      } catch {
+        // partial line
+      }
+    }
+  }
+  await reader.cancel();
+  return { timeout: true };
+}
+
+async function fetchOutput(jobId: string): Promise<Buffer | null> {
+  try {
+    const meta = await fetch(`${BASE}/api/v1/download/${jobId}/output-meta.json`);
+    if (meta.ok) {
+      const m = (await meta.json()) as { filename?: string };
+      if (m.filename) {
+        const dl = await fetch(`${BASE}/api/v1/download/${jobId}/${m.filename}`);
+        if (dl.ok) return Buffer.from(await dl.arrayBuffer());
+      }
+    }
+  } catch {
+    // fall through
+  }
+  return null;
+}
+
+async function run(toolId: string, file: string, settings: Record<string, unknown>) {
+  const buf = fs.readFileSync(file);
+  const fd = new FormData();
+  fd.append("file", new Blob([buf]), path.basename(file));
+  fd.append("settings", JSON.stringify(settings));
+  const res = await fetch(`${BASE}/api/v1/tools/${toolId}`, { method: "POST", body: fd });
+  if (res.status === 200) {
+    const j = (await res.json()) as { downloadUrl?: string };
+    if (j.downloadUrl) {
+      const dl = await fetch(`${BASE}${j.downloadUrl}`);
+      return { mode: "sync", out: Buffer.from(await dl.arrayBuffer()) };
+    }
+    return { mode: "sync", j };
+  }
+  if (res.status === 202) {
+    const j = (await res.json()) as { jobId: string };
+    const done = await pollSSE(j.jobId);
+    if (done.failed || done.timeout) return { mode: "async", failed: done };
+    const dlUrl =
+      (done.downloadUrl as string | undefined) ??
+      (done.result as { downloadUrl?: string } | undefined)?.downloadUrl;
+    if (dlUrl) {
+      const dl = await fetch(`${BASE}${dlUrl}`);
+      if (dl.ok) return { mode: "async", out: Buffer.from(await dl.arrayBuffer()), done };
+    }
+    const out = await fetchOutput(j.jobId);
+    return { mode: "async", out, done };
+  }
+  return { status: res.status, body: (await res.text()).slice(0, 200) };
+}
+
+const C = "tests/fixtures/content";
+
+const t = await run("transcribe-audio", `${C}/speech-10s.wav`, { outputFormat: "txt" });
+console.log(
+  "TRANSCRIBE:",
+  t.out ? `text="${t.out.toString("utf8").slice(0, 200)}"` : JSON.stringify(t).slice(0, 300),
+);
+
+const o = await run("ocr", `${C}/ocr-clean.png`, {});
+console.log(
+  "OCR:",
+  o.out ? `text="${o.out.toString("utf8").slice(0, 200)}"` : JSON.stringify(o).slice(0, 300),
+);
+
+const r = await run("remove-background", `${C}/portrait-color.jpg`, { outputFormat: "png" });
+if (r.out) {
+  fs.writeFileSync("/tmp/rembg-out.png", r.out);
+  let probe = "";
+  try {
+    probe = execFileSync(
+      "ffprobe",
+      ["-v", "quiet", "-show_entries", "stream=width,height,pix_fmt", "-of", "json", "/tmp/rembg-out.png"],
+      { encoding: "utf8" },
+    ).replace(/\s+/g, " ");
+  } catch (e) {
+    probe = `ffprobe-failed: ${String(e).slice(0, 80)}`;
+  }
+  console.log(`REMOVE-BG: png bytes=${r.out.length} ${probe}`);
+} else {
+  console.log("REMOVE-BG:", JSON.stringify(r).slice(0, 300));
+}
+
+// F9: ocr-pdf must not segfault and should return text
+const op = await run("ocr-pdf", `${C}/ocr-scanned.pdf`, {});
+console.log(
+  "OCR-PDF:",
+  op.out ? `out="${op.out.toString("utf8").slice(0, 160)}"` : JSON.stringify(op).slice(0, 300),
+);
+
+// F11: RAW processing must work (resize a .cr2 from the formats fixtures)
+const raw = await run("resize", "tests/fixtures/formats/sample.cr2", { width: 80 });
+console.log(
+  "RAW-RESIZE(cr2):",
+  raw.out ? `bytes=${raw.out.length}` : JSON.stringify(raw).slice(0, 300),
+);
+
+console.log("DONE");