test: run assembled setup harness scripts from a temp file, not bash -c argv (Windows MSYS2 8 KB truncation)

windows-free-tests (run 33907177851) failed in
test/setup-alias-name-uniqueness.test.ts with
  bash: -c: line 178: unexpected EOF while looking for matching `'
The harness slices functions out of `setup` and passed the joined script as
one `bash -c` argv element. The ownership gate grew that script from 6.7 KB
to 15.7 KB, and on Windows bash is an MSYS2 program: when its parent is a
non-MSYS process (bun), msys-2.0.dll's build_argv() runs any argument
containing `?*["'(){}` through globify()/glob(), which copies the pattern
into a fixed `Char patbuf[8192]` and silently stops after 8192 - MB_CUR_MAX
(8186 chars under C.UTF-8); GLOB_NOCHECK then returns the truncated text as
the argument. Character 8186 lands inside the single-quoted sed token on
line 178. Rebuilding the exact script with CI path shapes and cutting it at
8186-8190 characters reproduces the identical message locally; cmd.exe's
8191-UTF-16 cap and CreateProcess's 32767 do not fit the evidence.

Fix: test/helpers/bash-script.ts writes the script to a temp file and runs
`bash <path>` — a short glob-free argument that never enters globify. Every
setup harness that assembled a script for `bash -c` (11 files, 22 sites)
uses it; timeouts and env are preserved verbatim, spawn/timeout errors are
appended to stderr, temp cleanup is best-effort. `spawnSync('bash',
[<Windows absolute path>])` already passes on windows-latest in setup-help,
uninstall-windows-copies and the migration tests. The Windows-curated list
is byte-identical before and after.

Co-Authored-By: Claude Fable 5.1 <noreply@anthropic.com>

test/helpers/bash-script.ts

@@ -0,0 +1,60 @@
+/**
+ * Run an assembled bash script from a TEMP FILE — never via `bash -c <argv>`.
+ *
+ * Why: the setup harnesses slice functions out of `setup` and join them into
+ * one script. On Windows, bash is an MSYS2 program; when its parent is a
+ * non-MSYS process (bun), msys-2.0.dll's build_argv() runs every argument
+ * containing any of `?*["'(){}` through globify()/glob(). glob() copies the
+ * pattern into a fixed `Char patbuf[8192]` and silently stops after
+ * 8192 - MB_CUR_MAX (8186 characters under C.UTF-8); GLOB_NOCHECK then hands
+ * the truncated text to bash as the argument. Observed on windows-free-tests
+ * when the alias harness grew from 6.7 KB to 15.7 KB: the `-c` script was cut
+ * inside a single-quoted token on line 178 ("unexpected EOF while looking for
+ * matching `'"). A short, glob-character-free file path never enters
+ * globify, and bash reads the file's bytes directly, so quoting and encoding
+ * are never re-parsed by any argument layer. The same ~8186-char ceiling
+ * applies to any MSYS tool (sh, sed, awk, grep) spawned from bun on Windows
+ * with a long single argument.
+ *
+ * `timeout` is always set (test/spawnsync-timeout-tripwire.test.ts).
+ */
+import { spawnSync } from 'child_process';
+import * as fs from 'fs';
+import * as os from 'os';
+import * as path from 'path';
+
+export interface BashScriptResult {
+  status: number;
+  stdout: string;
+  stderr: string;
+  signal: NodeJS.Signals | null;
+}
+
+export interface BashScriptOptions {
+  timeout?: number;
+  env?: NodeJS.ProcessEnv;
+  cwd?: string;
+}
+
+export function runBashScript(script: string, opts: BashScriptOptions = {}): BashScriptResult {
+  const dir = fs.mkdtempSync(path.join(os.tmpdir(), 'gstack-bash-script-'));
+  const file = path.join(dir, 'script.sh');
+  // LF only: a stray CR would reach bash as part of a token.
+  fs.writeFileSync(file, script.replace(/\r\n/g, '\n'));
+  try {
+    const r = spawnSync('bash', [file], {
+      encoding: 'utf-8',
+      timeout: opts.timeout ?? 60_000,
+      ...(opts.env ? { env: opts.env } : {}),
+      ...(opts.cwd ? { cwd: opts.cwd } : {}),
+    });
+    // A spawn failure (bash missing) or a timeout kill has no bash stderr of
+    // its own; surface the cause instead of a bare status -1.
+    const stderr = (r.stderr ?? '') + (r.error ? `\n[spawn] ${r.error.message}` : '');
+    return { status: r.status ?? -1, stdout: r.stdout ?? '', stderr, signal: r.signal ?? null };
+  } finally {
+    // Best-effort: an AV scanner or indexer still holding script.sh on
+    // Windows must never turn a good result into an unlink error.
+    try { fs.rmSync(dir, { recursive: true, force: true }); } catch { /* best-effort temp cleanup */ }
+  }
+}

test/setup-alias-name-uniqueness.test.ts

@@ -16,7 +16,7 @@
  * corrupted the generated SKILL.md — the source files must stay byte-intact.
  */
 import { describe, test, expect, beforeAll, afterAll } from 'bun:test';
-import { spawnSync } from 'child_process';
+import { runBashScript } from './helpers/bash-script';
 import * as fs from 'fs';
 import * as os from 'os';
 import * as path from 'path';
@@ -74,7 +74,7 @@ beforeAll(() => {
     installOnce,
     installOnce,
   ].join('\n');
-  const result = spawnSync('bash', ['-c', script], { encoding: 'utf-8', timeout: 60_000 });
+  const result = runBashScript(script, { timeout: 60_000 });
   if (result.status !== 0) {
     throw new Error(`alias install failed: ${result.stderr}\n${result.stdout}`);
   }
@@ -168,7 +168,7 @@ describe('alias installs are rewritten copies (#2511, #2201)', () => {
         extractFn('link_claude_root_skill_alias'),
         `link_claude_root_skill_alias "${ROOT}" "${legacyDir}"`,
       ].join('\n');
-      const result = spawnSync('bash', ['-c', script], { encoding: 'utf-8', timeout: 30_000 });
+      const result = runBashScript(script, { timeout: 30_000 });
       expect(result.status).toBe(0);
 
       const aliasSkill = path.join(aliasDir, 'SKILL.md');

test/setup-bun-cmd-and-pipe-bugs.test.ts

@@ -1,5 +1,5 @@
 import { describe, test, expect } from 'bun:test';
-import { spawnSync } from 'child_process';
+import { runBashScript } from './helpers/bash-script';
 import * as fs from 'fs';
 import * as path from 'path';
 import * as os from 'os';
@@ -9,7 +9,7 @@ const SETUP_SRC = fs.readFileSync(path.join(ROOT, 'setup'), 'utf-8');
 
 // Run a bash snippet, return {stdout, stderr, status}.
 function runBash(script: string): { stdout: string; stderr: string; status: number } {
-  const r = spawnSync('bash', ['-c', script], { encoding: 'utf-8', timeout: 30_000 });
+  const r = runBashScript(script, { timeout: 30_000 });
   return { stdout: r.stdout || '', stderr: r.stderr || '', status: r.status ?? -1 };
 }
 

test/setup-claude-skill-assets.test.ts

@@ -21,7 +21,7 @@
  *     down to uselessness.
  */
 import { describe, test, expect, beforeAll, afterAll } from 'bun:test';
-import { spawnSync } from 'child_process';
+import { runBashScript } from './helpers/bash-script';
 import * as fs from 'fs';
 import * as os from 'os';
 import * as path from 'path';
@@ -82,7 +82,7 @@ beforeAll(() => {
     extractFn('link_claude_skill_dirs'),
     `link_claude_skill_dirs "${ROOT}" "${installDir}"`,
   ].join('\n');
-  const result = spawnSync('bash', ['-c', script], { encoding: 'utf-8', timeout: 60_000 });
+  const result = runBashScript(script, { timeout: 60_000 });
   if (result.status !== 0) {
     throw new Error(`installer functions failed: ${result.stderr}\n${result.stdout}`);
   }

test/setup-cleanup-orphans.test.ts

@@ -8,7 +8,7 @@
  * skills must stay.
  */
 import { describe, test, expect } from 'bun:test';
-import { spawnSync } from 'child_process';
+import { runBashScript } from './helpers/bash-script';
 import * as fs from 'fs';
 import * as os from 'os';
 import * as path from 'path';
@@ -72,10 +72,7 @@ describe.skipIf(process.platform === 'win32')('setup: cleanup_old_claude_symlink
       extractFn('cleanup_old_claude_symlinks'),
       `cleanup_old_claude_symlinks "${gstackArg}" "${skills}"`,
     ].join('\n');
-    const result = spawnSync('bash', ['-c', script], {
-      encoding: 'utf-8',
-      timeout: 5000,
-    });
+    const result = runBashScript(script, { timeout: 5000 });
     const names = fs.existsSync(skills)
       ? fs.readdirSync(skills).sort()
       : [];

test/setup-conductor-worktree.test.ts

@@ -1,5 +1,6 @@
 import { describe, test, expect } from 'bun:test';
 import { spawnSync } from 'child_process';
+import { runBashScript } from './helpers/bash-script';
 import * as path from 'path';
 import * as fs from 'fs';
 import * as os from 'os';
@@ -85,7 +86,7 @@ describe('setup: Conductor worktree guard', () => {
           echo "LINKED"
         fi
       `;
-      const result = spawnSync('bash', ['-c', script], { encoding: 'utf-8', timeout: 30_000 });
+      const result = runBashScript(script, { timeout: 30_000 });
       expect(result.status).toBe(0);
       expect(result.stdout.trim()).toBe('SKIP');
       // No child symlink leaked.
@@ -120,7 +121,7 @@ describe('setup: Conductor worktree guard', () => {
           echo "LINKED"
         fi
       `;
-      const result = spawnSync('bash', ['-c', script], { encoding: 'utf-8', timeout: 30_000 });
+      const result = runBashScript(script, { timeout: 30_000 });
       expect(result.status).toBe(0);
       expect(result.stdout.trim()).toBe('LINKED');
       expect(fs.lstatSync(dest).isSymbolicLink()).toBe(true);
@@ -159,7 +160,7 @@ describe('setup: Conductor worktree guard', () => {
           echo "LINKED"
         fi
       `;
-      const result = spawnSync('bash', ['-c', script], { encoding: 'utf-8', timeout: 30_000 });
+      const result = runBashScript(script, { timeout: 30_000 });
       expect(result.status).toBe(0);
       expect(result.stdout.trim()).toBe('LINKED');
       expect(fs.readlinkSync(dest)).toBe(source);
@@ -191,7 +192,7 @@ describe('setup: Conductor worktree guard', () => {
         fi
         echo "skip=$_SKIP_CLAUDE_REGISTER"
       `;
-      const result = spawnSync('bash', ['-c', script], { encoding: 'utf-8', timeout: 30_000 });
+      const result = runBashScript(script, { timeout: 30_000 });
       expect(result.status).toBe(0);
       expect(result.stdout.trim()).toBe('skip=0');
     } finally {

test/setup-emoji-font.test.ts

@@ -1,5 +1,5 @@
 import { describe, test, expect } from 'bun:test';
-import { spawnSync } from 'child_process';
+import { runBashScript } from './helpers/bash-script';
 import * as path from 'path';
 import * as fs from 'fs';
 import * as os from 'os';
@@ -137,11 +137,7 @@ describe.skipIf(process.platform === 'win32')('setup: ensure_emoji_font behavior
         'echo "INSTALLED=$EMOJI_FONT_INSTALLED"',
       ].join('\n');
 
-      const result = spawnSync('bash', ['-c', script], {
-        encoding: 'utf-8',
-        timeout: 10000,
-        env: { ...process.env, PATH: `${bin}:${process.env.PATH}` },
-      });
+      const result = runBashScript(script, { timeout: 10000, env: { ...process.env, PATH: `${bin}:${process.env.PATH}` } });
       const out = result.stdout ?? '';
       return {
         exit: Number((out.match(/EXIT=(\d+)/) ?? [])[1] ?? -1),

test/setup-link-ownership.test.ts

@@ -9,7 +9,7 @@
  * test/setup-cleanup-orphans.test.ts.
  */
 import { describe, test, expect } from 'bun:test';
-import { spawnSync } from 'child_process';
+import { runBashScript } from './helpers/bash-script';
 import * as fs from 'fs';
 import * as os from 'os';
 import * as path from 'path';
@@ -53,10 +53,7 @@ function mkTree(): { tmp: string; skills: string; payload: string } {
   return { tmp, skills, payload };
 }
 function bash(lines: string[], tmp: string) {
-  const r = spawnSync('bash', ['-c', lines.join('\n')], {
-    encoding: 'utf-8', timeout: 10_000,
-    env: { PATH: process.env.PATH ?? '', HOME: tmp, GSTACK_USER_RENDER_DIR: path.join(tmp, 'no-render') },
-  });
+  const r = runBashScript(lines.join('\n'), { timeout: 10_000, env: { PATH: process.env.PATH ?? '', HOME: tmp, GSTACK_USER_RENDER_DIR: path.join(tmp, 'no-render') } });
   // An extracted function calling a helper this harness forgot to extract must
   // fail loudly, not degrade into "foreign, skipped".
   if (/command not found/.test(r.stderr ?? '')) throw new Error(`harness drift (missing extracted helper):\n${r.stderr}`);

test/setup-playwright-best-effort.test.ts

@@ -17,6 +17,7 @@
  */
 import { describe, test, expect } from 'bun:test';
 import { spawnSync } from 'child_process';
+import { runBashScript } from './helpers/bash-script';
 import * as fs from 'fs';
 import * as os from 'os';
 import * as path from 'path';
@@ -403,7 +404,7 @@ function runEmojiStep(reason: string, fontOk: boolean): { stdout: string; stderr
     emoji,
     'echo "REACHED_END=1"',
   ].join('\n');
-  const r = spawnSync('bash', ['-c', script], { encoding: 'utf-8', timeout: 10_000 });
+  const r = runBashScript(script, { timeout: 10_000 });
   if (/command not found/.test(r.stderr ?? '')) throw new Error(`harness drift (missing extracted helper):\n${r.stderr}`);
   return { stdout: r.stdout ?? '', stderr: r.stderr ?? '', status: r.status ?? -1 };
 }
@@ -450,7 +451,7 @@ function runSummary(reason: string, telemetry: 'ok' | 'fail' | 'missing', prelud
       tail,
       'echo "REACHED_END=1"',
     ].join('\n');
-    const r = spawnSync('bash', ['-c', script], { encoding: 'utf-8', timeout: 10_000 });
+    const r = runBashScript(script, { timeout: 10_000 });
     if (/command not found/.test(r.stderr ?? '')) throw new Error(`harness drift (missing extracted helper):\n${r.stderr}`);
     const argv = fs.existsSync(argvFile) ? fs.readFileSync(argvFile, 'utf-8') : '';
     return { stdout: r.stdout ?? '', stderr: r.stderr ?? '', status: r.status ?? -1, argv };
@@ -582,7 +583,7 @@ function runLinker(opts: {
     `link_claude_skill_dirs "${payload}" "${skills}"`,
     'echo "FOREIGN=${_FOREIGN_SKIPPED_ENTRIES[*]:-}"',
   ].join('\n');
-  const r = spawnSync('bash', ['-c', script], { encoding: 'utf-8', timeout: 10_000, env: { PATH: process.env.PATH ?? '', HOME: tmp } });
+  const r = runBashScript(script, { timeout: 10_000, env: { PATH: process.env.PATH ?? '', HOME: tmp } });
   if (/command not found/.test(r.stderr ?? '')) throw new Error(`harness drift (missing extracted helper):\n${r.stderr}`);
   return { status: r.status ?? -1, stdout: r.stdout ?? '', stderr: r.stderr ?? '', skills, payload, tmp };
 }
@@ -628,12 +629,12 @@ describe.skipIf(process.platform === 'win32')('setup: .gstack-owned ownership ma
       fs.writeFileSync(path.join(r.skills, 'review', 'SKILL.md'), '---\nname: review\n---\n# mine, hand-written\n');
       fs.mkdirSync(path.join(r.skills, 'my-own'));
       fs.writeFileSync(path.join(r.skills, 'my-own', 'SKILL.md'), '---\nname: my-own\n---\n');
-      const flip = spawnSync('bash', ['-c', [
+      const flip = runBashScript([
         'set -e', 'IS_WINDOWS=1',
         extractFn('_gstack_link_target_abs'), extractFn('_gstack_target_is_ours'), extractFn('_gstack_dir_only_links'), extractFn('_cleanup_linked_dir'), extractFn('_gstack_generated_header'), extractFn('_cleanup_weak_dir'), extractFn('_backup_skill_md'), '_BACKED_UP_SKILL_MDS=()', '_SKILL_BACKUP_ROOT="$HOME/.gstack/backups/skills/test"',
         extractFn('cleanup_old_claude_symlinks'),
         `cleanup_old_claude_symlinks "${r.payload}" "${r.skills}"`,
-      ].join('\n')], { encoding: 'utf-8', timeout: 10_000 });
+      ].join('\n'), { timeout: 10_000 });
       expect(flip.status).toBe(0);
       expect(flip.stdout).toContain('cleaned up old entries:');
       expect(flip.stdout).toContain('qa');

test/setup-windows-fallback.test.ts

@@ -1,5 +1,5 @@
 import { describe, test, expect } from 'bun:test';
-import { spawnSync } from 'child_process';
+import { runBashScript } from './helpers/bash-script';
 import * as path from 'path';
 import * as fs from 'fs';
 import * as os from 'os';
@@ -95,10 +95,7 @@ describe.skipIf(process.platform === 'win32')('setup: _link_or_copy helper — b
       const helper = extractHelper();
       // IS_WINDOWS must exist as a shell-readable var before sourcing.
       const script = `IS_WINDOWS=${isWindows}\n${helper}\n_link_or_copy "${src}" "${dst}"\n`;
-      const result = spawnSync('bash', ['-c', script], {
-        encoding: 'utf-8',
-        timeout: 5000,
-      });
+      const result = runBashScript(script, { timeout: 5000 });
       const lst = fs.lstatSync(dst, { throwIfNoEntry: false });
       return {
         ok: result.status === 0,

test/setup-windows-rerun-refresh.test.ts

@@ -16,7 +16,7 @@
  * factory/opencode can't silently regress.
  */
 import { describe, test, expect } from 'bun:test';
-import { spawnSync } from 'child_process';
+import { runBashScript } from './helpers/bash-script';
 import * as fs from 'fs';
 import * as os from 'os';
 import * as path from 'path';
@@ -165,7 +165,7 @@ function runInstaller(
     ...fns.map(extractFn),
     invocation,
   ].join('\n');
-  const r = spawnSync('bash', ['-c', script], { encoding: 'utf-8', timeout: 15_000 });
+  const r = runBashScript(script, { timeout: 15_000 });
   return { status: r.status, stdout: r.stdout, stderr: r.stderr };
 }
 

test/user-render-out-dir-install.test.ts

@@ -14,6 +14,7 @@
  */
 import { describe, test, expect } from 'bun:test';
 import { spawnSync } from 'child_process';
+import { runBashScript } from './helpers/bash-script';
 import * as fs from 'fs';
 import * as os from 'os';
 import * as path from 'path';
@@ -86,7 +87,7 @@ describe(':user render targets the out-dir, never the checkout (#2569)', () => {
           extractFn(src, '_swap_in_render'),
           `_swap_in_render "${live}" "${fresh}"`,
         ].join('\n');
-        const r = spawnSync('bash', ['-c', script], { encoding: 'utf-8', timeout: 15_000 });
+        const r = runBashScript(script, { timeout: 15_000 });
         expect(r.status).toBe(0);
         // Live dir now serves the fresh render at the SAME path (links into
         // it stay valid), tmp and .old are gone.
@@ -126,7 +127,7 @@ describe(':user render targets the out-dir, never the checkout (#2569)', () => {
         '  echo "render failed — previous render left in place" >&2',
         'fi',
       ].join('\n');
-      const r = spawnSync('bash', ['-c', script], { encoding: 'utf-8', timeout: 15_000 });
+      const r = runBashScript(script, { timeout: 15_000 });
       expect(r.status).toBe(0);
       expect(fs.readFileSync(path.join(live, 'ship', 'SKILL.md'), 'utf-8')).toBe('previous-render\n');
       // The installed symlink still resolves — the skill set did not vanish.
@@ -191,7 +192,7 @@ describe('link_claude_skill_dirs prefers rendered SKILL.md (behavior)', () => {
         extractFn(SETUP_SRC, 'link_claude_skill_dirs'),
         `link_claude_skill_dirs "${src}" "${skills}"`,
       ].join('\n');
-      const r = spawnSync('bash', ['-c', script], { encoding: 'utf-8', timeout: 15_000 });
+      const r = runBashScript(script, { timeout: 15_000 });
       expect(r.status).toBe(0);
 
       expect(fs.readFileSync(path.join(skills, 'alpha', 'SKILL.md'), 'utf-8')).toContain('rendered-alpha');