@aion0/forge 0.4.1 → 0.4.2

package/RELEASE_NOTES.md

@@ -1,11 +1,15 @@
-# Forge v0.4.1
+# Forge v0.4.2
 
 Released: 2026-03-21
 
-## Changes since v0.4.0
+## 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
 
+### Documentation
+- fix: auto-recover from PTY exhaustion + add npm ENOTEMPTY troubleshooting
 
-**Full Changelog**: https://github.com/aiwatching/forge/compare/v0.4.0...v0.4.1
+
+**Full Changelog**: https://github.com/aiwatching/forge/compare/v0.4.1...v0.4.2

package/bin/forge-server.mjs

@@ -72,23 +72,6 @@ const LOG_FILE = join(DATA_DIR, 'forge.log');
 
 process.chdir(ROOT);
 
-// ── Init logger (timestamps + file output) ──
-try {
-  const { initLogger } = await import('../lib/logger.ts');
-  initLogger();
-} catch {
-  // logger.ts is TypeScript, may not load directly in .mjs — fallback inline
-  const _key = Symbol.for('forge-logger-init');
-  if (!globalThis[_key]) {
-    globalThis[_key] = true;
-    const _origLog = console.log, _origErr = console.error, _origWarn = console.warn;
-    const _ts = () => new Date().toISOString().replace('T', ' ').slice(0, 19);
-    console.log = (...a) => _origLog(`[${_ts()}]`, ...a);
-    console.error = (...a) => _origErr(`[${_ts()}]`, ...a);
-    console.warn = (...a) => _origWarn(`[${_ts()}]`, ...a);
-  }
-}
-
 // ── 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

@@ -15,13 +15,18 @@ export function initLogger() {
   (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/next-env.d.ts

@@ -1,6 +1,6 @@
 /// <reference types="next" />
 /// <reference types="next/image-types/global" />
-import "./.next/types/routes.d.ts";
+import "./.next/dev/types/routes.d.ts";
 
 // NOTE: This file should not be edited
 // see https://nextjs.org/docs/app/api-reference/config/typescript for more information.

package/package.json

@@ -1,6 +1,6 @@
 {
   "name": "@aion0/forge",
-  "version": "0.4.1",
+  "version": "0.4.2",
   "description": "Unified AI workflow platform — multi-model task orchestration, persistent sessions, web terminal, remote access",
   "type": "module",
   "scripts": {