@aion0/forge 0.4.0 → 0.4.2

package/RELEASE_NOTES.md

@@ -1,8 +1,15 @@
-# Forge v0.4.0
+# Forge v0.4.2
 
 Released: 2026-03-21
 
-## Changes since v0.3.7
+## Changes since v0.4.1
 
+### Bug Fixes
+- fix: prevent double console.log wrapping in production mode
+- fix: auto-recover from PTY exhaustion + add npm ENOTEMPTY troubleshooting
 
-**Full Changelog**: https://github.com/aiwatching/forge/compare/v0.3.7...v0.4.0
+### Documentation
+- fix: auto-recover from PTY exhaustion + add npm ENOTEMPTY troubleshooting
+
+
+**Full Changelog**: https://github.com/aiwatching/forge/compare/v0.4.1...v0.4.2

package/bin/forge-server.mjs

@@ -72,15 +72,6 @@ const LOG_FILE = join(DATA_DIR, 'forge.log');
 
 process.chdir(ROOT);
 
-// ── Add timestamps to all console output ──
-const origLog = console.log;
-const origError = console.error;
-const origWarn = console.warn;
-const ts = () => new Date().toISOString().replace('T', ' ').slice(0, 19);
-console.log = (...args) => origLog(`[${ts()}]`, ...args);
-console.error = (...args) => origError(`[${ts()}]`, ...args);
-console.warn = (...args) => origWarn(`[${ts()}]`, ...args);
-
 // ── Migrate old layout (~/.forge/*) to new (~/.forge/data/*) ──
 if (!getArg('--dir')) {
   const oldSettings = join(homedir(), '.forge', 'settings.yaml');

package/lib/help-docs/10-troubleshooting.md

@@ -61,6 +61,13 @@ rm -rf .next
 pnpm build  # or forge server rebuild
 ```
 
+### npm install fails with ENOTEMPTY
+Previous install was interrupted. Clean up and retry:
+```bash
+rm -rf $(npm root -g)/@aion0/forge $(npm root -g)/@aion0/.forge-*
+npm install -g @aion0/forge
+```
+
 ## Logs
 
 - Background server: `~/.forge/data/forge.log`

package/lib/logger.ts

@@ -7,20 +7,26 @@
 import { appendFileSync, mkdirSync, existsSync } from 'node:fs';
 import { join } from 'node:path';
 
-let initialized = false;
+// Use globalThis to prevent double-init across forge-server.mjs and init.ts
+const loggerKey = Symbol.for('forge-logger-init');
 
 export function initLogger() {
-  if (initialized) return;
-  initialized = true;
+  if ((globalThis as any)[loggerKey]) return;
+  (globalThis as any)[loggerKey] = true;
 
   // Determine log file path
+  // In production mode (FORGE_EXTERNAL_SERVICES=1), stdout is already redirected to forge.log
+  // by forge-server.mjs, so we only need to write to file in dev mode
+  const isProduction = process.env.FORGE_EXTERNAL_SERVICES === '1';
   let logFile: string | null = null;
-  try {
-    const { getDataDir } = require('./dirs');
-    const dataDir = getDataDir();
-    if (!existsSync(dataDir)) mkdirSync(dataDir, { recursive: true });
-    logFile = join(dataDir, 'forge.log');
-  } catch {}
+  if (!isProduction) {
+    try {
+      const { getDataDir } = require('./dirs');
+      const dataDir = getDataDir();
+      if (!existsSync(dataDir)) mkdirSync(dataDir, { recursive: true });
+      logFile = join(dataDir, 'forge.log');
+    } catch {}
+  }
 
   const origLog = console.log;
   const origError = console.error;

package/lib/terminal-standalone.ts

@@ -149,10 +149,36 @@ function createTmuxSession(cols: number, rows: number): string {
 
   const id = Date.now().toString(36) + Math.random().toString(36).slice(2, 6);
   const name = `${SESSION_PREFIX}${id}`;
-  execSync(`${TMUX} new-session -d -s ${name} -x ${cols} -y ${rows}`, {
-    cwd: getDefaultCwd(),
-    env: { ...process.env, TERM: 'xterm-256color' },
-  });
+  try {
+    execSync(`${TMUX} new-session -d -s ${name} -x ${cols} -y ${rows}`, {
+      cwd: getDefaultCwd(),
+      env: { ...process.env, TERM: 'xterm-256color' },
+    });
+  } catch (e: any) {
+    const msg = e.stderr?.toString() || e.message || '';
+    if (msg.includes('posix_spawn') || msg.includes('fork failed') || msg.includes('No such file')) {
+      // PTY exhausted — aggressive cleanup: kill ALL idle sessions
+      console.error(`[terminal] PTY exhausted, cleaning up all idle sessions...`);
+      const all = listTmuxSessions();
+      for (const s of all) {
+        if (!s.attached) {
+          killTmuxSession(s.name);
+          console.log(`[terminal] Killed idle session: ${s.name}`);
+        }
+      }
+      // Retry once
+      try {
+        execSync(`${TMUX} new-session -d -s ${name} -x ${cols} -y ${rows}`, {
+          cwd: getDefaultCwd(),
+          env: { ...process.env, TERM: 'xterm-256color' },
+        });
+      } catch {
+        throw new Error('Failed to create terminal session. PTY devices exhausted. Run: sudo sysctl kern.tty.ptmx_max=2048');
+      }
+    } else {
+      throw e;
+    }
+  }
   // Enable mouse scrolling and set large scrollback buffer
   try {
     execSync(`${TMUX} set-option -t ${name} mouse on 2>/dev/null`);

package/package.json

@@ -1,6 +1,6 @@
 {
   "name": "@aion0/forge",
-  "version": "0.4.0",
+  "version": "0.4.2",
   "description": "Unified AI workflow platform — multi-model task orchestration, persistent sessions, web terminal, remote access",
   "type": "module",
   "scripts": {