fix: patch 7 critical bugs affecting all non-dev-machine users and Windows

1. Fix esbuild inlining build-machine __dirname as string literal — use
   CJS-compatible runtime banner with require("node:url").fileURLToPath
   across worker-service, mcp-server, and context-generator builds.

2. Fix isMainModule check missing .cjs extension and Windows backslash
   path normalization.

3. Wrap extractLastMessage in try-catch to prevent infinite Stop hook
   feedback loop on malformed transcripts (exit 0 instead of exit 2).

4. Replace heavy SessionEnd hook (Node→Bun→1.7MB CJS→HTTP) with
   lightweight inline node -e one-liner (~200ms vs >1s).

5. Add 7 Gemini/OpenRouter error patterns to unrecoverablePatterns
   circuit breaker to prevent 77K+ retry loops on expired API keys.

6. Preserve CLAUDE_CODE_OAUTH_TOKEN and CLAUDE_CODE_GIT_BASH_PATH in
   sanitizeEnv instead of stripping them with the CLAUDE_CODE_ prefix.

7. Use PowerShell -EncodedCommand for spawnDaemon to fix path quoting
   when Windows usernames contain spaces.

Closes #1515, #1495, #1475, #1465, #1500, #1513, #1512, #1450, #1460,
#1486, #1449, #1481, #1451, #1480, #1453, #1445

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

src/cli/handlers/summarize.ts

@@ -35,7 +35,13 @@ export const summarizeHandler: EventHandler = {
     // Extract last assistant message from transcript (the work Claude did)
     // Note: "user" messages in transcripts are mostly tool_results, not actual user input.
     // The user's original request is already stored in user_prompts table.
-    const lastAssistantMessage = extractLastMessage(transcriptPath, 'assistant', true);
+    let lastAssistantMessage = '';
+    try {
+      lastAssistantMessage = extractLastMessage(transcriptPath, 'assistant', true);
+    } catch (err) {
+      logger.warn('HOOK', `Failed to extract last assistant message: ${err instanceof Error ? err.message : err}`);
+      return { continue: true, suppressOutput: true, exitCode: HOOK_EXIT_CODES.SUCCESS };
+    }
 
     logger.dataIn('HOOK', 'Stop: Requesting summary', {
       hasLastAssistantMessage: !!lastAssistantMessage

src/services/infrastructure/ProcessManager.ts

@@ -646,12 +646,12 @@ export function spawnDaemon(
       return undefined;
     }
 
-    const escapedRuntimePath = runtimePath.replace(/'/g, "''");
-    const escapedScriptPath = scriptPath.replace(/'/g, "''");
-    const psCommand = `Start-Process -FilePath '${escapedRuntimePath}' -ArgumentList '${escapedScriptPath}','--daemon' -WindowStyle Hidden`;
+    // Use -EncodedCommand to avoid all shell quoting issues with spaces in paths
+    const psScript = `Start-Process -FilePath '${runtimePath.replace(/'/g, "''")}' -ArgumentList @('${scriptPath.replace(/'/g, "''")}','--daemon') -WindowStyle Hidden`;
+    const encodedCommand = Buffer.from(psScript, 'utf16le').toString('base64');
 
     try {
-      execSync(`powershell -NoProfile -Command "${psCommand}"`, {
+      execSync(`powershell -NoProfile -EncodedCommand ${encodedCommand}`, {
         stdio: 'ignore',
         windowsHide: true,
         env

src/services/worker-service.ts

@@ -578,6 +578,13 @@ export class WorkerService {
           'ENOENT',
           'spawn',
           'Invalid API key',
+          'API_KEY_INVALID',
+          'API key expired',
+          'API key not valid',
+          'PERMISSION_DENIED',
+          'Gemini API error: 400',
+          'Gemini API error: 401',
+          'Gemini API error: 403',
           'FOREIGN KEY constraint failed',
         ];
         if (unrecoverablePatterns.some(pattern => errorMessage.includes(pattern))) {
@@ -1262,7 +1269,10 @@ async function main() {
 // Check if running as main module in both ESM and CommonJS
 const isMainModule = typeof require !== 'undefined' && typeof module !== 'undefined'
   ? require.main === module || !module.parent
-  : import.meta.url === `file://${process.argv[1]}` || process.argv[1]?.endsWith('worker-service');
+  : import.meta.url === `file://${process.argv[1]}`
+    || process.argv[1]?.endsWith('worker-service')
+    || process.argv[1]?.endsWith('worker-service.cjs')
+    || process.argv[1]?.replaceAll('\\', '/') === __filename?.replaceAll('\\', '/');
 
 if (isMainModule) {
   main().catch((error) => {

src/supervisor/env-sanitizer.ts

@@ -6,11 +6,18 @@ export const ENV_EXACT_MATCHES = new Set([
   'MCP_SESSION_ID',
 ]);
 
+/** Vars that start with CLAUDE_CODE_ but must be preserved for subprocess auth/tooling */
+export const ENV_PRESERVE = new Set([
+  'CLAUDE_CODE_OAUTH_TOKEN',
+  'CLAUDE_CODE_GIT_BASH_PATH',
+]);
+
 export function sanitizeEnv(env: NodeJS.ProcessEnv = process.env): NodeJS.ProcessEnv {
   const sanitized: NodeJS.ProcessEnv = {};
 
   for (const [key, value] of Object.entries(env)) {
     if (value === undefined) continue;
+    if (ENV_PRESERVE.has(key)) { sanitized[key] = value; continue; }
     if (ENV_EXACT_MATCHES.has(key)) continue;
     if (ENV_PREFIXES.some(prefix => key.startsWith(prefix))) continue;
     sanitized[key] = value;