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166c6655e8 fix(desktop): surface install failures hidden by curl-pipe exit codes (#2892 )

Ubuntu Doctor reports `Install failed at verify: The installer finished,
but Buzz still could not use claude-code (observed: CLI missing)` while
the `cli` step shows success. The `cli` step is lying.

## The masking

Every CLI install command is a pipe — `curl -fsSL
https://claude.ai/install.sh | bash`
(`managed_agents/discovery.rs:109`), `… | sh` for Codex (`:141`), `… |
CONFIGURE=false bash` for Goose (`:75`). `install_shell_command` ran
them through `bash -l -c` with no `pipefail`, so the pipeline's exit
status was the **right-hand** side's. A `curl` that fails — or that
isn't on the child's PATH at all — feeds `bash` an empty stdin, and
`bash` with nothing to run exits 0:

```
$ /bin/bash -l -c 'curl -fsSL https://nonexistent.invalid/x.sh | bash'; echo $?
curl: (6) Could not resolve host: nonexistent.invalid
0
$ PATH=/tmp/empty /bin/bash -l -c 'curl -fsSL https://claude.ai/install.sh | bash'; echo $?
bash: line 1: curl: command not found
0
```

`run_install_command` records exit 0 as `success: true`, the adapter
step then installs fine (it uses Buzz's own bundled Node, no system PATH
needed), and `post_install_verification` correctly reports the CLI is
absent. The user is handed a `verify` riddle instead of curl's error,
which is why diagnosing this required three rounds of guessing.

Install commands now run under `set -o pipefail`, so the left-hand
side's failure is the step's failure and `InstallStepResult.stderr`
carries the vendor's own message. `SHELLOPTS` is not exported by either
shell, so the piped-to vendor script still runs with its default
options. The Windows PowerShell install path
(`install_powershell_command`) bypasses this shell and is untouched.

## The PATH collapse it was hiding

`install_shell_command` composes the child's PATH and calls
`cmd.env("PATH", …)`, which **replaces** rather than extends.
`should_use_inherited` was `is_windows && !had_shell_path &&
has_local_context`, so on Unix the inherited process PATH was never
appended. When `login_shell_path()` returns `None` — a login shell that
exits non-zero or prints nothing, which a GUI-launched process can
easily hit via `~/.profile` — the child's entire PATH becomes Buzz's two
managed Node dirs. There is no `curl`, `sh`, `sha256sum`, or `tar` in
either, so every curl-pipe install fails, and before this PR it failed
invisibly.

The `is_windows` requirement is dropped: the inherited PATH is the floor
whenever no login-shell PATH was obtained, on every OS. Both existing
suppressions are kept — a login-shell PATH present still suppresses it
(no doubling), and no home/exe context still suppresses it (never
manufacture a PATH from ambient state alone). Inherited entries stay
**last**, so managed dirs keep precedence.

The other caller, `build_augmented_path` (`runtime/path.rs:148`, feeding
agent spawns and CLI probes), reads correctly under the new rule for the
same reason: it only gains the inherited PATH in the case where it would
otherwise hand a child a PATH with no native entries. When a login-shell
PATH exists — the normal case on macOS and Linux — its output is
unchanged, which `unix_shell_path_suppresses_inherited_fallback` pins.

## Scope

This fixes the reporting defect and the PATH floor. The specific
environment failure on the affected Ubuntu box is still being diagnosed
and is deliberately not addressed here; the point of this change is that
the next attempt produces the real error instead of a `verify` riddle.

One interaction worth noting: `install_failure_is_retryable` retries any
failure that carries an exit code, so a pipefail-surfaced curl failure
now gets 3 attempts with backoff — correct for transient network blips,
and harmless for hard failures.

`desktop/scripts/check-file-sizes.mjs` ratchets the `agent_discovery.rs`
ceiling 1836 → 1895 for the added tests.

---------

Signed-off-by: Will Pfleger <pfleger.will@gmail.com>
Co-authored-by: npub1mn7jgtj4w2pd0g0zeuhxsa6jy6p0rewxz4kujt98my82ahfmp72sxjexk7 <dcfd242e557282d7a1e2cf2e6877522682f1e5c6156dc92ca7d90eaedd3b0f95@buzz.block.builderlab.xyz>

2026-07-26 12:28:30 -04:00