v1.52.2.0 fix(make-pdf): render emoji instead of tofu (▯) on Linux (#1787)

* fix(make-pdf): emoji font fallback in print CSS

Emoji code points rendered as .notdef tofu (▯) because the body and
@top-center font stacks had no emoji family for Chromium to fall back to.
Add SANS_STACK / CJK_STACK / EMOJI_FAMILIES constants (one source of truth
per family list) and append the emoji families before the generic
sans-serif in the two stacks that can hold emoji. The @bottom-* boxes hold
counters / a fixed CONFIDENTIAL string, so they share SANS_STACK without
emoji. Non-emoji output is byte-identical.

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

* feat(setup): auto-install color-emoji font on Linux

macOS and Windows ship a color-emoji font; most Linux distros/containers
ship none, so make-pdf emits tofu there. ensure_emoji_font() best-effort
installs fonts-noto-color-emoji (apt, with dnf/pacman/apk fallbacks) and
refreshes the fontconfig cache. Hardened: Linux-only guard, GSTACK_SKIP_FONTS
escape hatch, fc-match color=True detection (the broad fc-list query
false-matched LastResort), sudo -n so a password prompt fails fast instead
of hanging, DEBIAN_FRONTEND=noninteractive, timeout 30 on apt update, and
fc-cache under sudo. Warns instead of failing. After a fresh install,
refresh_browse_daemon_for_fonts() runs 'browse stop' so the next render
spawns a Chromium that sees the new font (font fallback is process-cached).

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

* test(make-pdf): emoji render gate (pdffonts + pixel proof)

pdftotext is a false oracle for emoji: Skia preserves the Unicode in the
text cluster even when the glyph drew as .notdef tofu, so extraction passes
on a broken render. The gate instead asserts (1) pdffonts shows an emoji
family embedded and (2) pdftoppm rasterizes the page to color (measured
~1650 saturated pixels vs ~0 for tofu). pdfimages is not used: macOS embeds
color emoji as Type 3 fonts, so it lists nothing even on a correct render.
Adds resolvePopplerTool() (DRY resolver, returns null for clean skips) and
a fixture exercising FE0F variation-selector emoji. Skips cleanly when
poppler tools or a color-emoji font are unavailable.

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

* ci(make-pdf): install emoji font + run emoji gate on Ubuntu

Install fonts-noto-color-emoji before Chromium launches on the Ubuntu leg
(macOS already ships Apple Color Emoji), refresh fontconfig, and log the
fc-match result. Run the whole make-pdf/test/e2e/ dir so the emoji gate runs
alongside the combined-features copy-paste gate.

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

* harden(make-pdf): emoji gate + font install per adversarial review

Codex adversarial pass on the implementation diff flagged five robustness
gaps, all fixed here:
- emoji-gate skipped green in CI when poppler/font prerequisites were absent,
  which could let the tofu regression ship behind a green build. Missing
  prerequisites are now a HARD FAILURE when process.env.CI is set; local dev
  still skips cleanly.
- execFileSync children (make-pdf, pdffonts, pdftoppm, fc-match) had no
  timeout; a wedged binary or hostile GSTACK_*_BIN override could hang the
  job past Bun's test timeout. Each child now has a 25s ceiling.
- PPM parser trusted header tokens blindly; malformed/variant output gave a
  silently-wrong count. Now validates magic/dimensions/maxval and pixel-buffer
  length, handles header comments, throws a hard diagnostic on mismatch.
- predictable /tmp paths were collision/symlink-prone; now mkdtempSync under
  /tmp (kept under /tmp for browse's validateOutputPath allowlist).
- only apt-get update was timeout-wrapped; dnf/pacman/apk installs and apt
  install can hang on locks/mirrors. All package installs now timeout-bound.

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

* chore: bump version and changelog (v1.52.2.0)

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

* docs(make-pdf): document color-emoji font requirement + GSTACK_SKIP_FONTS

Extend the Linux font note to cover the color-emoji font that make-pdf
emoji rendering needs: setup auto-installs fonts-noto-color-emoji, the
print CSS falls back through Apple/Segoe/Noto emoji families, and
GSTACK_SKIP_FONTS=1 opts out. Edit the .tmpl and regenerate SKILL.md.

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

---------

Co-authored-by: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

CHANGELOG.md

@@ -1,5 +1,41 @@
 # Changelog
 
+## [1.52.2.0] - 2026-05-29
+
+## **Emoji render in make-pdf PDFs on every platform. Linux stops printing tofu boxes, and setup installs the font for you.**
+
+make-pdf used to render emoji code points as `.notdef` tofu (▯) on Linux. The cause was a missing fallback: the print CSS font stacks had no emoji family, and most Linux distros and containers ship no color-emoji font at all, so Skia drew empty boxes in every header and table that used emoji. Now the body and running-header stacks fall back through Apple Color Emoji, Segoe UI Emoji, and Noto Color Emoji, and `./setup` best-effort installs `fonts-noto-color-emoji` on Linux (apt, with dnf/pacman/apk fallbacks), refreshes the font cache, and restarts a running browser daemon so the next render picks it up. macOS and Windows already shipped an emoji font and are unchanged. Non-emoji Unicode (em dash, times, arrow, bullet, ellipsis) always worked and still does.
+
+## The numbers that matter
+
+Source: the emoji render gate, `bun test make-pdf/test/e2e/emoji-gate.test.ts`, rendering a fixture of color emoji at 100 dpi.
+
+| Metric | Before | After | Δ |
+|---|---|---|---|
+| Saturated (color) pixels in the rendered emoji region | ~0 (tofu) | ~1,650 | real color render |
+| Platforms that render emoji correctly | macOS, Windows | macOS, Windows, Linux | +Linux |
+| Emoji-bearing font stacks with a fallback family | 0 | 2 | body + running header |
+| Deterministic render-proof gates | 0 | 1 | pdffonts + pixel |
+
+A tofu box is a near-monochrome outline (close to zero colored pixels). A real emoji render lands about 1,650 saturated pixels. The gate asserts both that an emoji font embedded (`pdffonts`) and that the page actually rasterizes to color (`pdftoppm`), because PDF text extraction passes even when the glyph drew as tofu, so it cannot be trusted as the proof.
+
+## What this means for builders
+
+If you generate PDFs on Linux or inside a container, emoji in section headers and table status columns now render instead of ▯. Run `./setup` once on Linux to install the font; there is nothing to do on macOS or Windows. Set `GSTACK_SKIP_FONTS=1` to opt out on locked-down or offline machines.
+
+### Itemized changes
+
+#### Added
+- `ensure_emoji_font()` in `setup`: Linux color-emoji install across apt/dnf/pacman/apk, `fc-match` color-font detection (idempotent, skips when a real color font already resolves), `fc-cache` refresh under sudo, and a browse-daemon restart so a running render server sees the new font. Opt out with `GSTACK_SKIP_FONTS=1`. Non-interactive `sudo -n` and timeout-bound package calls so it never hangs setup.
+- Emoji render gate (`make-pdf/test/e2e/emoji-gate.test.ts`) with a variation-selector (`❤️`, FE0F) fixture: asserts an emoji font embeds and the page rasterizes to color. Hard-fails in CI when poppler or the font is missing, so prerequisite drift can't hide a regression behind a green build.
+- `resolvePopplerTool()` resolver for `pdffonts` / `pdfimages` / `pdftoppm`.
+- The Ubuntu make-pdf CI gate installs `fonts-noto-color-emoji` before Chromium launches.
+
+#### Changed
+- Print CSS body and `@top-center` running-header font stacks fall back through Apple Color Emoji, Segoe UI Emoji, and Noto Color Emoji, placed before the generic `sans-serif`. All font stacks are now composed from shared constants.
+
+#### Fixed
+- make-pdf no longer renders emoji as `.notdef` tofu (▯) on Linux.
 ## [1.52.1.0] - 2026-05-27
 
 ## **Brain-aware planning lands. Five planning skills read structured context from any personal gbrain before asking — same questions, smarter answers, no token tax.**