Fix QVAC Worker

docs/QVAC.md

@@ -100,6 +100,21 @@ npm run ensure:qvac-bare-runtimes   # force-install all QVAC host binaries
 npm run make:client:darwin-arm64
 ```
 
+### Worker RPC timeout (`RPC initialization timed out after 30000ms`)
+
+`bundleSdk` writes **absolute** `file:///build-machine/...` imports into
+`qvac/worker.entry.mjs`. Off the build host Bare cannot load them, so the worker
+never handshakes.
+
+Fix (already wired into forge + `build-qvac-worker`):
+
+```bash
+node scripts/rewrite-qvac-worker-entry.cjs --force-portable
+```
+
+That rewrites the entry to **relative** `../node_modules/@qvac/sdk/...` imports
+so the packaged app is self-contained.
+
 ### Native host matrix (LLM prebuilds)
 
 `@qvac/llm-llamacpp` ships Bare prebuilds for:

forge.config.cjs

@@ -483,6 +483,16 @@ module.exports = {
             `[forge] failed to ensure bare-runtime-${packageHost} for QVAC: ${err?.message || err}`
           )
         }
+        // bundleSdk (QvacForgePlugin) may regenerate absolute file:// imports —
+        // always re-write a portable entry before packaging copies files.
+        try {
+          require('./scripts/rewrite-qvac-worker-entry.cjs').ensurePortableWorkerEntry({
+            root: __dirname,
+            forcePortable: true,
+          })
+        } catch (err) {
+          console.warn('[forge] prePackage portable worker rewrite:', err?.message || err)
+        }
       }
 
       if (process.env.PEARDATA_SKIP_PREPACKAGE_BUNDLE === '1') {
@@ -533,6 +543,23 @@ module.exports = {
         )
       }
 
+      // Portable worker.entry.mjs: strip absolute file:///build-machine paths
+      // (bundleSdk emits those; Bare then dies → RPC init timeout 30s)
+      if (qvacEnabled) {
+        try {
+          const { ensurePortableWorkerEntry } = require('./scripts/rewrite-qvac-worker-entry.cjs')
+          const wr = ensurePortableWorkerEntry({
+            root: buildPath,
+            forcePortable: true,
+          })
+          console.log(
+            `[forge] portable QVAC worker entry: ${wr.reason || 'ok'} → ${wr.path}`
+          )
+        } catch (err) {
+          console.warn('[forge] rewrite-qvac-worker-entry failed:', err?.message || err)
+        }
+      }
+
       // --- bare-runtime platform binary (QVAC issue #1492) -------------------
       // If the platform package was missed by ignore/prune, copy it from the
       // project tree. Fail hard when QVAC is enabled so CI never ships a
@@ -565,6 +592,40 @@ module.exports = {
         }
         console.log(`[forge] verified bare-runtime-${host} binary in package`)
       }
+
+      // Fail if worker still has build-machine absolute imports
+      if (qvacEnabled) {
+        const entry = path.join(buildPath, 'qvac', 'worker.entry.mjs')
+        if (fs.existsSync(entry)) {
+          const body = fs.readFileSync(entry, 'utf8')
+          if (/file:\/\/\/Users\/|file:\/\/\/home\/|file:\/\/\/[A-Za-z]:\//.test(body)) {
+            throw new Error(
+              `[forge] qvac/worker.entry.mjs still has absolute file:// imports — ` +
+                `Bare worker will time out on other machines. Run: ` +
+                `node scripts/rewrite-qvac-worker-entry.cjs --force-portable`
+            )
+          }
+          console.log('[forge] verified portable qvac/worker.entry.mjs (no absolute file://)')
+        } else {
+          throw new Error(
+            `[forge] missing qvac/worker.entry.mjs in package — Bare RPC cannot start`
+          )
+        }
+        // Ensure @qvac/sdk paths the worker imports exist
+        const needFiles = [
+          'node_modules/@qvac/sdk/dist/server/worker-core.js',
+          'node_modules/@qvac/sdk/dist/server/plugins/index.js',
+          'node_modules/@qvac/sdk/dist/logging/index.js',
+          'node_modules/@qvac/sdk/dist/server/bare/plugins/llamacpp-completion/plugin.js',
+        ]
+        for (const rel of needFiles) {
+          if (!fs.existsSync(path.join(buildPath, rel))) {
+            throw new Error(
+              `[forge] QVAC package missing ${rel} (required by portable worker entry)`
+            )
+          }
+        }
+      }
     },
     postPackage: async (_forgeConfig, options) => {
       const platform = options.platform || process.platform

qvac/worker.entry.mjs

@@ -1,26 +1,25 @@
 /**
- * QVAC SDK Worker Entry (auto-generated)
- * Generated by: @qvac/sdk/commands bundleSdk
- * Plugins: 1
+ * QVAC SDK Worker Entry (portable)
+ * Relative imports only — safe for packaged Electron / CI clients.
+ * Plugins: 1 — @qvac/sdk/llamacpp-completion/plugin
  *
-*   - @qvac/sdk/llamacpp-completion/plugin
+ * Regenerated by scripts/rewrite-qvac-worker-entry.cjs
+ * (bundleSdk emits absolute file:// URLs that break off the build machine)
  */
 
-import { initializeWorkerCore, ensureRPCSetup } from "file:///Users/raven/dev/peardata/node_modules/@qvac/sdk/dist/server/worker-core.js";
-import { registerPlugin } from "file:///Users/raven/dev/peardata/node_modules/@qvac/sdk/dist/server/plugins/index.js";
-import { getServerLogger } from "file:///Users/raven/dev/peardata/node_modules/@qvac/sdk/dist/logging/index.js";
+import { initializeWorkerCore, ensureRPCSetup } from '../node_modules/@qvac/sdk/dist/server/worker-core.js'
+import { registerPlugin } from '../node_modules/@qvac/sdk/dist/server/plugins/index.js'
+import { getServerLogger } from '../node_modules/@qvac/sdk/dist/logging/index.js'
+import { llmPlugin } from '../node_modules/@qvac/sdk/dist/server/bare/plugins/llamacpp-completion/plugin.js'
 
-import { llmPlugin } from "file:///Users/raven/dev/peardata/node_modules/@qvac/sdk/dist/server/bare/plugins/llamacpp-completion/plugin.js";
+const { hasRPCConfig } = initializeWorkerCore()
 
-const { hasRPCConfig } = initializeWorkerCore();
+const logger = getServerLogger()
+logger.info('🐻 QVAC Worker (portable bundle)')
+logger.info('📦 Plugins: 1 (llamacpp-completion)')
 
-const logger = getServerLogger();
-logger.info("🐻 QVAC Worker (custom bundle)");
-logger.info("📦 Plugins: 1");
+registerPlugin(llmPlugin)
 
-registerPlugin(llmPlugin);
-
-// Auto-setup RPC if config present
 if (hasRPCConfig) {
-  ensureRPCSetup();
+  ensureRPCSetup()
 }

scripts/build-qvac-worker.cjs

@@ -51,6 +51,9 @@ async function main() {
     `[build-qvac-worker] ok addons=${(result.addons || []).length} bundle=${result.bundlePath || '(default)'}`
   )
 
+  // bundleSdk writes absolute file:// imports — rewrite for packaged / CI clients
+  require('./rewrite-qvac-worker-entry.cjs').ensurePortableWorkerEntry({ root })
+
   if (typeof commands.verifyBundle === 'function') {
     const verify = await commands.verifyBundle({
       projectRoot: root,

scripts/rewrite-qvac-worker-entry.cjs

@@ -0,0 +1,197 @@
+#!/usr/bin/env node
+/**
+ * Make qvac/worker.entry.mjs portable for packaged Electron / CI clients.
+ *
+ * `@qvac/sdk` bundleSdk writes absolute `file:///…/node_modules/@qvac/…` imports
+ * so bare-pack can resolve addons on the *build* machine. Those paths break as
+ * soon as the app is shipped elsewhere → Bare worker dies →
+ *   "RPC initialization timed out after 30000ms — the worker process may have failed to start"
+ *
+ * This rewrites those URLs to relative paths from qvac/worker.entry.mjs, e.g.
+ *   ../node_modules/@qvac/sdk/dist/server/worker-core.js
+ *
+ * Usage:
+ *   node scripts/rewrite-qvac-worker-entry.cjs
+ *   node scripts/rewrite-qvac-worker-entry.cjs --entry /path/to/qvac/worker.entry.mjs
+ *   node scripts/rewrite-qvac-worker-entry.cjs --root /path/to/app
+ */
+'use strict'
+
+const fs = require('fs')
+const path = require('path')
+const { pathToFileURL, fileURLToPath } = require('url')
+
+const rootDefault = path.resolve(__dirname, '..')
+
+/**
+ * @param {string} entryPath absolute path to worker.entry.mjs
+ * @returns {{ rewritten: number, path: string, ok: boolean, reason?: string }}
+ */
+function rewriteWorkerEntry(entryPath) {
+  if (!fs.existsSync(entryPath)) {
+    return { rewritten: 0, path: entryPath, ok: false, reason: 'missing' }
+  }
+  const original = fs.readFileSync(entryPath, 'utf8')
+  const entryDir = path.dirname(entryPath)
+
+  let count = 0
+  const next = original.replace(/file:\/\/\/[^\s"'`]+|file:\/\/[^\s"'`]+/g, (href) => {
+    try {
+      let filePath
+      try {
+        filePath = fileURLToPath(href)
+      } catch {
+        return href
+      }
+      if (!fs.existsSync(filePath)) {
+        // Still rewrite if it points under a known node_modules layout
+        // (CI may rewrite before files are fully staged)
+      }
+      let rel = path.relative(entryDir, filePath)
+      if (!rel || rel === path.basename(filePath)) {
+        // same dir
+        rel = `./${path.basename(filePath)}`
+      } else if (!rel.startsWith('.') && !path.isAbsolute(rel)) {
+        rel = `./${rel}`
+      }
+      // ESM wants POSIX separators
+      rel = rel.split(path.sep).join('/')
+      // Prefer bare relative specifier (no file://) — Bare resolves these
+      count++
+      return rel
+    } catch {
+      return href
+    }
+  })
+
+  if (count === 0 && !/file:\/\//.test(original)) {
+    // Already portable — ensure relative @qvac paths exist or write canonical entry
+    if (
+      original.includes('../node_modules/@qvac/sdk/') ||
+      original.includes('@qvac/sdk/')
+    ) {
+      return { rewritten: 0, path: entryPath, ok: true, reason: 'already-portable' }
+    }
+  }
+
+  if (next !== original) {
+    fs.writeFileSync(entryPath, next, 'utf8')
+  }
+
+  // Guard: no absolute build-machine paths left
+  if (/file:\/\/\/Users\/|file:\/\/\/home\/|file:\/\/\/[A-Za-z]:\//.test(next)) {
+    return {
+      rewritten: count,
+      path: entryPath,
+      ok: false,
+      reason: 'absolute file:// paths remain after rewrite',
+    }
+  }
+
+  return { rewritten: count, path: entryPath, ok: true }
+}
+
+/**
+ * Write a known-good portable LLM-only worker entry (matches qvac.config.json).
+ * Used when rewrite fails or entry is missing.
+ * @param {string} entryPath
+ */
+function writePortableLlmWorkerEntry(entryPath) {
+  const content = `/**
+ * QVAC SDK Worker Entry (portable)
+ * Relative imports only — safe for packaged Electron / CI clients.
+ * Plugins: 1 — @qvac/sdk/llamacpp-completion/plugin
+ *
+ * Regenerated by scripts/rewrite-qvac-worker-entry.cjs
+ * (bundleSdk emits absolute file:// URLs that break off the build machine)
+ */
+
+import { initializeWorkerCore, ensureRPCSetup } from '../node_modules/@qvac/sdk/dist/server/worker-core.js'
+import { registerPlugin } from '../node_modules/@qvac/sdk/dist/server/plugins/index.js'
+import { getServerLogger } from '../node_modules/@qvac/sdk/dist/logging/index.js'
+import { llmPlugin } from '../node_modules/@qvac/sdk/dist/server/bare/plugins/llamacpp-completion/plugin.js'
+
+const { hasRPCConfig } = initializeWorkerCore()
+
+const logger = getServerLogger()
+logger.info('🐻 QVAC Worker (portable bundle)')
+logger.info('📦 Plugins: 1 (llamacpp-completion)')
+
+registerPlugin(llmPlugin)
+
+if (hasRPCConfig) {
+  ensureRPCSetup()
+}
+`
+  fs.mkdirSync(path.dirname(entryPath), { recursive: true })
+  fs.writeFileSync(entryPath, content, 'utf8')
+  return entryPath
+}
+
+/**
+ * @param {{ root?: string, entry?: string, forcePortable?: boolean }} [opts]
+ */
+function ensurePortableWorkerEntry(opts = {}) {
+  const root = opts.root || rootDefault
+  const entryPath =
+    opts.entry || path.join(root, 'qvac', 'worker.entry.mjs')
+
+  if (opts.forcePortable || !fs.existsSync(entryPath)) {
+    writePortableLlmWorkerEntry(entryPath)
+    console.log(`[rewrite-qvac-worker] wrote portable entry: ${entryPath}`)
+    return { ok: true, path: entryPath, rewritten: -1, reason: 'wrote-portable' }
+  }
+
+  const result = rewriteWorkerEntry(entryPath)
+  if (!result.ok && result.reason !== 'missing') {
+    console.warn(
+      `[rewrite-qvac-worker] rewrite incomplete (${result.reason}) — writing portable LLM entry`
+    )
+    writePortableLlmWorkerEntry(entryPath)
+    return { ok: true, path: entryPath, rewritten: result.rewritten, reason: 'fallback-portable' }
+  }
+  if (result.reason === 'missing') {
+    writePortableLlmWorkerEntry(entryPath)
+    return { ok: true, path: entryPath, rewritten: -1, reason: 'wrote-portable' }
+  }
+
+  console.log(
+    `[rewrite-qvac-worker] ${entryPath}: rewritten=${result.rewritten} (${result.reason || 'ok'})`
+  )
+  return result
+}
+
+function parseArgs(argv) {
+  /** @type {{ root?: string, entry?: string, forcePortable?: boolean }} */
+  const opts = {}
+  for (let i = 0; i < argv.length; i++) {
+    const a = argv[i]
+    if (a === '--root' && argv[i + 1]) opts.root = path.resolve(argv[++i])
+    else if (a.startsWith('--root=')) opts.root = path.resolve(a.slice(7))
+    else if (a === '--entry' && argv[i + 1]) opts.entry = path.resolve(argv[++i])
+    else if (a.startsWith('--entry=')) opts.entry = path.resolve(a.slice(8))
+    else if (a === '--force-portable') opts.forcePortable = true
+    else if (a === '--help' || a === '-h') {
+      console.log(
+        'Usage: node scripts/rewrite-qvac-worker-entry.cjs [--root DIR] [--entry FILE] [--force-portable]'
+      )
+      process.exit(0)
+    }
+  }
+  return opts
+}
+
+if (require.main === module) {
+  const result = ensurePortableWorkerEntry(parseArgs(process.argv.slice(2)))
+  if (!result.ok) {
+    console.error('[rewrite-qvac-worker] FAILED', result)
+    process.exit(1)
+  }
+}
+
+module.exports = {
+  rewriteWorkerEntry,
+  writePortableLlmWorkerEntry,
+  ensurePortableWorkerEntry,
+  pathToFileURL,
+}