fix(bin): route remaining Windows-reachable mkdirSync sites through mkdirpSync

Sweep follow-up to #2641's lib/fs-utils.ts helper: bun on Windows throws EEXIST from a recursive mkdir on an existing dir, so every unguarded recursive mkdirSync on a Windows-reachable path is a latent crash. Converted: bin/gstack-decision-log (unguarded, runs on every decision log — the second call on any machine hits the pre-existing projects dir), bin/gstack-evidence logsDir + ledger dir sites, and bin/gstack-redact-prepush's skip-log site (already try-wrapped, so its failure mode was a silent skip-log loss rather than a crash — the fix makes the log survive). The ~15 remaining gbrain/mac-lane sites are deliberately left alone.

Regression: fs-utils.test.ts drives gstack-decision-log twice, the second run under the bun-Windows EEXIST preload fixture — the pre-sweep code exits 1 with EEXIST there; verified red against v1.68.3.0.

bin/gstack-decision-log

@@ -14,8 +14,8 @@
  * validateDecide; a rejected decision exits 1 with a message, nothing persisted.
  */
 
-import { mkdirSync } from "fs";
 import { dirname } from "path";
+import { mkdirpSync } from "../lib/fs-utils";
 import { spawnSync } from "child_process";
 import {
   decisionPaths,
@@ -33,7 +33,9 @@ const HERE = import.meta.dir;
 const args = process.argv.slice(2);
 const slug = resolveSlug(`${HERE}/gstack-slug`);
 const paths = decisionPaths(slug);
-mkdirSync(dirname(paths.log), { recursive: true });
+// mkdirpSync, not bare mkdirSync: bun on Windows throws EEXIST from a
+// recursive mkdir on an existing dir (#2635), and this runs on every log call.
+mkdirpSync(dirname(paths.log));
 
 function enqueue(): void {
   // Fire-and-forget cross-machine sync (no-op when artifacts_sync is off).

bin/gstack-evidence

@@ -34,7 +34,8 @@
  * in the ledger; it cannot prove that an expected lane ever ran.
  */
 
-import { mkdirSync, openSync, writeSync, closeSync, readdirSync, statSync, unlinkSync, chmodSync, readFileSync } from "fs";
+import { openSync, writeSync, closeSync, readdirSync, statSync, unlinkSync, chmodSync, readFileSync } from "fs";
+import { mkdirpSync } from "../lib/fs-utils";
 import { join, dirname } from "path";
 import { spawnSync } from "child_process";
 import { appendJsonl, readJsonl } from "../lib/jsonl-store";
@@ -137,7 +138,7 @@ function pruneOldLogs(logsDir: string): void {
 /** Exclusive-open a collision-safe log file. Returns undefined on failure. */
 function openLog(logsDir: string, label: string, cmdSha: string): { fd: number; path: string } | undefined {
   try {
-    mkdirSync(logsDir, { recursive: true });
+    mkdirpSync(logsDir);
     pruneOldLogs(logsDir);
     const ts = new Date().toISOString().replace(/[:.]/g, "-");
     const base = `${ts}-${label}-${process.pid}-${cmdSha.slice(0, 8)}`;
@@ -266,7 +267,7 @@ async function cmdRun(argv: string[]): Promise<number> {
   let paths: ReturnType<typeof ledgerPath> | undefined;
   try {
     paths = ledgerPath();
-    mkdirSync(paths.dir, { recursive: true });
+    mkdirpSync(paths.dir);
   } catch (e: any) {
     warn(`ledger setup failed (${e?.message ?? e}) — result will not be recorded`);
   }

bin/gstack-redact-prepush

@@ -30,6 +30,7 @@ import * as fs from "fs";
 import * as os from "os";
 import * as path from "path";
 import { scan, type Finding } from "../lib/redact-engine";
+import { mkdirpSync } from "../lib/fs-utils";
 
 const ZERO = /^0+$/;
 // The canonical empty-tree object; diffing against it yields all content as added.
@@ -349,7 +350,10 @@ function logSkip(reason: string): void {
   try {
     const home = process.env.GSTACK_HOME || path.join(os.homedir(), ".gstack");
     const dir = path.join(home, "security");
-    fs.mkdirSync(dir, { recursive: true });
+    // mkdirpSync, not bare mkdirSync: bun-on-Windows EEXIST (#2635). This site
+    // is try-wrapped by the caller, so the old failure was a silent skip-log
+    // loss rather than a crash — the fix makes the log survive, not un-crash.
+    mkdirpSync(dir);
     fs.appendFileSync(
       path.join(dir, "prepush-skip.jsonl"),
       JSON.stringify({ ts: new Date().toISOString(), reason }) + "\n",

test/fs-utils.test.ts

@@ -61,6 +61,33 @@ describe("mkdirpSync", () => {
   });
 });
 
+describe("swept mkdirp sites under bun-on-Windows EEXIST semantics (#2635)", () => {
+  const DECISION_LOG = path.resolve(import.meta.dir, "..", "bin", "gstack-decision-log");
+
+  test("decision-log still writes when its projects dir already exists", () => {
+    // Proves the sweep WIRING, not just the helper: the first call creates
+    // ~/.gstack/projects/<slug>/, the second hits the emulated Windows EEXIST
+    // on that pre-existing dir — bare mkdirSync crashed here before the sweep.
+    const base = tmpdir();
+    try {
+      const work = path.join(base, "work");
+      fs.mkdirSync(work, { recursive: true });
+      const payload = '{"decision":"eexist probe","rationale":"r","scope":"repo","source":"user"}';
+      const env = { ...process.env, HOME: base };
+      const first = spawnSync("bun", [DECISION_LOG, payload], { cwd: work, encoding: "utf8", env });
+      expect(first.status).toBe(0);
+      const second = spawnSync(
+        "bun", ["--preload", EEXIST_PRELOAD, DECISION_LOG, payload],
+        { cwd: work, encoding: "utf8", env },
+      );
+      expect(second.status).toBe(0);
+      expect(second.stderr ?? "").not.toContain("EEXIST");
+    } finally {
+      fs.rmSync(base, { recursive: true, force: true });
+    }
+  });
+});
+
 describe("install-prepush-hook under bun-on-Windows EEXIST semantics (#2635)", () => {
   test("install succeeds when .git/hooks already exists, existing hook preserved", () => {
     const base = tmpdir();