@rangojs/router 0.0.0-experimental.9eb4192e → 0.0.0-experimental.a014d2b7

package/src/vite/router-discovery.ts

@@ -16,7 +16,10 @@ import {
   formatNestedRouterConflictError,
   findNestedRouterConflict,
   findRouterFiles,
+  createScanFilter,
 } from "../build/generate-route-types.js";
+import { firstCodeMatchIndex } from "../build/route-types/source-scan.js";
+import { injectClientDebugFlag } from "./inject-client-debug.js";
 import { createVersionPlugin } from "./plugins/version-plugin.js";
 import { createVirtualStubPlugin } from "./plugins/virtual-stub-plugin.js";
 import {
@@ -35,7 +38,10 @@ import {
   type DiscoveryState,
   type PluginOptions,
 } from "./discovery/state.js";
-import { consumeSelfGenWrite } from "./discovery/self-gen-tracking.js";
+import {
+  consumeSelfGenWrite,
+  peekSelfGenWrite,
+} from "./discovery/self-gen-tracking.js";
 import { discoverRouters } from "./discovery/discover-routers.js";
 import {
   writeCombinedRouteTypesWithTracking,
@@ -47,13 +53,19 @@ import {
   generatePerRouterModule,
 } from "./discovery/virtual-module-codegen.js";
 import { postprocessBundle } from "./discovery/bundle-postprocess.js";
+import { createDiscoveryGate } from "./discovery/gate-state.js";
 import { resetStagedBuildAssets } from "./utils/prerender-utils.js";
-import { createRangoDebugger, timed, timedSync } from "./debug.js";
+import { resolveRscEntryFromConfig } from "./utils/shared-utils.js";
+import {
+  pickForwardedRunnerConfig,
+  selectForwardableResolvePlugins,
+} from "./utils/forward-user-plugins.js";
+import { createRangoDebugger, timed, timedSync, NS } from "./debug.js";
 
-const debugDiscovery = createRangoDebugger("rango:discovery");
-const debugRoutes = createRangoDebugger("rango:routes");
-const debugBuild = createRangoDebugger("rango:build");
-const debugDev = createRangoDebugger("rango:dev");
+const debugDiscovery = createRangoDebugger(NS.discovery);
+const debugRoutes = createRangoDebugger(NS.routes);
+const debugBuild = createRangoDebugger(NS.build);
+const debugDev = createRangoDebugger(NS.dev);
 
 export { VIRTUAL_ROUTES_MANIFEST_ID };
 
@@ -95,7 +107,7 @@ function ensureCloudflareProtocolLoaderRegistered(): void {
     // register() requires Node 18.19+ / 20.6+. Older Node still has the
     // Vite transform as primary defense.
     console.warn(
-      `[rsc-router] Could not register Node ESM loader hook for cloudflare:* imports (${err?.message ?? err}). Falling back to Vite transform only.`,
+      `[rango] Could not register Node ESM loader hook for cloudflare:* imports (${err?.message ?? err}). Falling back to Vite transform only.`,
     );
   }
 }
@@ -125,14 +137,26 @@ async function createTempRscServer(
   // instead of crashing Node's native loader.
   ensureCloudflareProtocolLoaderRegistered();
   const { default: rsc } = await import("@vitejs/plugin-rsc");
+  // Mirror the user's resolution config + plugins so discovery (and the
+  // prerender/static rendering that shares this runner) resolves modules the
+  // same way the real environment does. Falls back to the legacy alias-only
+  // behavior if configResolved hasn't populated the parity slice yet.
+  const runnerConfig = state.userRunnerConfig;
+  const resolveConfig = runnerConfig?.resolve ?? {
+    alias: state.userResolveAlias,
+  };
+  const oxcConfig = runnerConfig?.oxc ?? {
+    jsx: { runtime: "automatic", importSource: "react" },
+  };
   return createViteServer({
     root: state.projectRoot,
     configFile: false,
     server: { middlewareMode: true },
     appType: "custom",
     logLevel: "silent",
-    resolve: { alias: state.userResolveAlias },
-    esbuild: { jsx: "automatic", jsxImportSource: "react" },
+    resolve: resolveConfig,
+    ...(runnerConfig?.define ? { define: runnerConfig.define } : {}),
+    oxc: oxcConfig as any,
     ...(options.cacheDir && { cacheDir: options.cacheDir }),
     plugins: [
       rsc({
@@ -151,6 +175,10 @@ async function createTempRscServer(
       // runtime. forceBuild produces hashed IDs for production bundle consistency.
       exposeInternalIds(options.forceBuild ? { forceBuild: true } : undefined),
       exposeRouterId(),
+      // Forwarded user resolution plugins (e.g. vite-tsconfig-paths). Stripped
+      // to resolveId/load and placed last so framework resolution runs first;
+      // Vite re-sorts by `enforce`, so `enforce: "pre"` resolvers still lead.
+      ...state.userResolvePlugins,
     ],
   });
 }
@@ -178,7 +206,7 @@ async function resolveBuildEnv(
   if (option === "auto") {
     if (factoryCtx.preset !== "cloudflare") {
       throw new Error(
-        '[rsc-router] buildEnv: "auto" is only supported with preset: "cloudflare". ' +
+        '[rango] buildEnv: "auto" is only supported with preset: "cloudflare". ' +
           "Use a factory function or plain object for other presets.",
       );
     }
@@ -200,7 +228,7 @@ async function resolveBuildEnv(
       };
     } catch (err: any) {
       throw new Error(
-        '[rsc-router] buildEnv: "auto" requires wrangler to be installed.\n' +
+        '[rango] buildEnv: "auto" requires wrangler to be installed.\n' +
           `Install it with: pnpm add -D wrangler\n${err.message}`,
       );
     }
@@ -252,7 +280,7 @@ async function releaseBuildEnv(s: DiscoveryState): Promise<void> {
     try {
       await s.buildEnvDispose();
     } catch (err: any) {
-      console.warn(`[rsc-router] buildEnv dispose failed: ${err.message}`);
+      console.warn(`[rango] buildEnv dispose failed: ${err.message}`);
     }
     s.buildEnvDispose = null;
   }
@@ -283,45 +311,50 @@ export function createRouterDiscoveryPlugin(
   return {
     name: "@rangojs/router:discovery",
 
-    config() {
-      const config: any = {
-        define: {
-          __RANGO_DEBUG__: JSON.stringify(!!process.env.INTERNAL_RANGO_DEBUG),
-        },
-      };
-      // Prerender/static handler modules are bundled naturally with the
-      // rest of the RSC entry.  A previous design forced them into dedicated
-      // __prerender-handlers / __static-handlers chunks via manualChunks,
-      // but Rollup hoisted all shared dependencies into those chunks,
-      // inflating them to ~1 MB with active runtime code.  Handler code is
-      // evicted in closeBundle regardless of which chunk it lands in.
-      return config;
+    // Make INTERNAL_RANGO_DEBUG reach the CLIENT debug logs by just setting the
+    // env var. See injectClientDebugFlag: bakes the resolved flag into the
+    // internal-debug module so FE debug no longer depends on Vite delivering the
+    // `__RANGO_DEBUG__` define to the client (which it does only as an injected
+    // global whose presence varies across consumer setups). Runs in dev and build.
+    transform(_code, id) {
+      return injectClientDebugFlag(id);
     },
 
     configResolved(config) {
       s.projectRoot = config.root;
+      // Compile the optional discovery scan filter (glob include/exclude) now
+      // that the project root is known. findRouterFiles() below — and the
+      // build/HMR rediscovery paths — honor s.scanFilter.
+      s.scanFilter = opts?.discovery
+        ? createScanFilter(s.projectRoot, opts.discovery)
+        : undefined;
       s.isBuildMode = config.command === "build";
       viteCommand = config.command as "serve" | "build";
       viteMode = config.mode;
       // Capture user's resolve aliases for the temp server
       s.userResolveAlias = config.resolve.alias;
+      // Capture the data-only resolution config (resolve.*, define, oxc) and
+      // the user's resolution plugins (resolveId/load) so the discovery temp
+      // server resolves modules the same way the real environment does.
+      // Without this, both flavors of user resolution are absent during
+      // discovery/prerender/static rendering even though they apply at request
+      // time: third-party resolvers (e.g. vite-tsconfig-paths, forwarded as
+      // plugins) and Vite 8's native resolve.tsconfigPaths (forwarded in the
+      // data slice). See utils/forward-user-plugins.ts.
+      s.userRunnerConfig = pickForwardedRunnerConfig(config);
+      s.userResolvePlugins = selectForwardableResolvePlugins(
+        config.plugins as any,
+      );
       // Node preset: pick up auto-discovered router path from the config() hook.
       // The auto-discover plugin runs in config() using Vite's resolved root,
       // populating the mutable ref before configResolved fires.
       if (!s.resolvedEntryPath && opts?.routerPathRef?.path) {
         s.resolvedEntryPath = opts.routerPathRef.path;
       }
-      // Cloudflare preset: read entry from resolved environment config.
-      // The @cloudflare/vite-plugin reads wrangler config (toml/json/jsonc)
-      // and sets optimizeDeps.entries on the RSC environment.
+      // Cloudflare preset: entry comes from the resolved RSC env config.
       if (!s.resolvedEntryPath) {
-        const rscEnvConfig = (config.environments as any)?.["rsc"];
-        const entries = rscEnvConfig?.optimizeDeps?.entries;
-        if (typeof entries === "string") {
-          s.resolvedEntryPath = entries;
-        } else if (Array.isArray(entries) && entries.length > 0) {
-          s.resolvedEntryPath = entries[0];
-        }
+        const entry = resolveRscEntryFromConfig(config);
+        if (entry) s.resolvedEntryPath = entry;
       }
       // Generate combined named-routes.gen.ts from static source parsing.
       // Runs before the dev server starts so the gen file exists immediately for IDE.
@@ -360,6 +393,17 @@ export function createRouterDiscoveryPlugin(
         resolveDiscovery = resolve;
       });
 
+      // Manifest-readiness gate + rediscovery scheduler.
+      // The virtual:rsc-router/routes-manifest module's `load()` hook
+      // awaits `s.discoveryDone`; the gate is reset on each discovery
+      // cycle so workerd's HMR reloads block until the new gen file is
+      // written. State machine + transitions are extracted into
+      // ./discovery/gate-state.ts and unit-tested there — see the
+      // module's JSDoc for the four-flag contract.
+      const gate = createDiscoveryGate(s, debugDiscovery);
+      const beginDiscoveryGate = gate.beginGate;
+      const resolveDiscoveryGate = gate.resolveGate;
+
       // Compute dev server origin from resolved URLs (preferred) or config port (fallback).
       // Called after discovery (or in the load hook) when the server may be listening.
       const getDevServerOrigin = () =>
@@ -382,10 +426,104 @@ export function createRouterDiscoveryPlugin(
         releaseBuildEnv(s).catch(() => {});
       });
 
+      // Mirror the build-path contract (the buildStart hook below, which sets
+      // __rscRouterDiscoveryActive before running user modules):
+      // set __rscRouterDiscoveryActive before running user modules so any
+      // module-level router.reverse() calls return a placeholder instead
+      // of throwing. The temp Vite server's module runner has its own
+      // module context; the flag must be on globalThis to cross that
+      // boundary. Cleared in finally so the dev request handlers run with
+      // strict reverse() semantics afterwards.
+      async function importEntryAndRegistry(tempRscEnv: any): Promise<void> {
+        const flagAlreadySet = !!(globalThis as any).__rscRouterDiscoveryActive;
+        if (!flagAlreadySet) {
+          (globalThis as any).__rscRouterDiscoveryActive = true;
+        }
+        try {
+          debugDiscovery?.(
+            "importEntryAndRegistry: importing entry (flag=%s)",
+            (globalThis as any).__rscRouterDiscoveryActive ?? false,
+          );
+          await tempRscEnv.runner.import(s.resolvedEntryPath!);
+          debugDiscovery?.(
+            "importEntryAndRegistry: entry import OK, fetching RouterRegistry",
+          );
+          const serverMod = await tempRscEnv.runner.import(
+            "@rangojs/router/server",
+          );
+          prerenderNodeRegistry = serverMod.RouterRegistry;
+          debugDiscovery?.(
+            "importEntryAndRegistry: registry size=%d",
+            prerenderNodeRegistry?.size ?? 0,
+          );
+        } finally {
+          if (!flagAlreadySet) {
+            delete (globalThis as any).__rscRouterDiscoveryActive;
+            debugDiscovery?.(
+              "importEntryAndRegistry: cleared __rscRouterDiscoveryActive",
+            );
+          }
+        }
+      }
+
       async function getOrCreateTempServer(): Promise<any | null> {
-        if (prerenderNodeRegistry) {
-          return (prerenderTempServer.environments as any)?.rsc ?? null;
+        // Reuse path: if a temp server is already alive, prefer reusing
+        // it over orphaning the existing instance and spinning up a new
+        // one. This handles two cases:
+        //
+        //   1. Steady-state cache hit (cold-start completed, registry
+        //      cached) — return the env immediately.
+        //   2. Recovery from a failed refresh: refreshTempRscEnv() may
+        //      have invalidated and nulled the registry, then thrown
+        //      during importEntryAndRegistry. Without reuse, the next
+        //      call would `createTempRscServer` and overwrite the
+        //      handle, leaking the previous server. Try to re-import on
+        //      the existing runner first; only if THAT fails do we
+        //      close the orphan and create new.
+        if (prerenderTempServer) {
+          const existingEnv = (prerenderTempServer.environments as any)?.rsc;
+          if (existingEnv?.runner) {
+            if (prerenderNodeRegistry) {
+              debugDiscovery?.(
+                "getOrCreateTempServer: cached temp runner reused",
+              );
+              return existingEnv;
+            }
+            // Server alive but registry missing — likely after a prior
+            // refresh's invalidate + import threw. Try to re-import.
+            debugDiscovery?.(
+              "getOrCreateTempServer: server alive but registry missing — re-importing",
+            );
+            try {
+              await importEntryAndRegistry(existingEnv);
+              return existingEnv;
+            } catch (err: any) {
+              debugDiscovery?.(
+                "getOrCreateTempServer: reuse import failed (%s) — closing orphan and creating fresh",
+                err?.message ?? String(err),
+              );
+              await prerenderTempServer.close().catch(() => {});
+              prerenderTempServer = null;
+              prerenderNodeRegistry = null;
+              // Fall through to create-new path below.
+            }
+          } else {
+            // Server reference exists but its rsc env is unhealthy
+            // (no runner). Close and recreate.
+            debugDiscovery?.(
+              "getOrCreateTempServer: existing server has no rsc.runner — closing and recreating",
+            );
+            await prerenderTempServer.close().catch(() => {});
+            prerenderTempServer = null;
+            prerenderNodeRegistry = null;
+          }
         }
+
+        // Create path: no existing temp server (or just nullified above).
+        debugDiscovery?.(
+          "getOrCreateTempServer: creating new temp server, entry=%s",
+          s.resolvedEntryPath ?? "(unset)",
+        );
         try {
           prerenderTempServer = await createTempRscServer(s, {
             cacheDir: "node_modules/.vite_prerender",
@@ -393,21 +531,120 @@ export function createRouterDiscoveryPlugin(
 
           const tempRscEnv = (prerenderTempServer.environments as any)?.rsc;
           if (tempRscEnv?.runner) {
-            await tempRscEnv.runner.import(s.resolvedEntryPath!);
-            const serverMod = await tempRscEnv.runner.import(
-              "@rangojs/router/server",
-            );
-            prerenderNodeRegistry = serverMod.RouterRegistry;
+            await importEntryAndRegistry(tempRscEnv);
             return tempRscEnv;
           }
+          debugDiscovery?.(
+            "getOrCreateTempServer: tempRscEnv.runner unavailable",
+          );
         } catch (err: any) {
-          console.warn(
-            `[rsc-router] Failed to create temp runner: ${err.message}`,
+          debugDiscovery?.(
+            "getOrCreateTempServer: FAILED message=%s",
+            err.message,
           );
+          console.warn(`[rango] Failed to create temp runner: ${err.message}`);
         }
         return null;
       }
 
+      // Clear the package-level singleton registries that survive a Vite
+      // moduleGraph.invalidateAll(). createRouter() / createHostRouter()
+      // call .set(id, ...) on these Maps; for "router removed" or
+      // "router id changed" edits, the OLD entry would persist after
+      // re-import without an explicit .clear(), leaving ghost routes
+      // in discoverRouters' output.
+      //
+      // We import the same module the runner imports, so the .clear()
+      // here mutates the same Map the freshly re-imported entry will
+      // populate.
+      async function clearTempRegistries(tempRscEnv: any): Promise<void> {
+        try {
+          const serverMod = await tempRscEnv.runner.import(
+            "@rangojs/router/server",
+          );
+          if (typeof serverMod?.RouterRegistry?.clear === "function") {
+            serverMod.RouterRegistry.clear();
+          }
+          if (typeof serverMod?.HostRouterRegistry?.clear === "function") {
+            serverMod.HostRouterRegistry.clear();
+          }
+          debugDiscovery?.(
+            "clearTempRegistries: cleared RouterRegistry + HostRouterRegistry",
+          );
+        } catch (err: any) {
+          // Non-fatal: if the import fails here, importEntryAndRegistry
+          // below will fail loudly with the same root cause and the
+          // caller will surface it.
+          debugDiscovery?.(
+            "clearTempRegistries: import @rangojs/router/server failed (%s)",
+            err?.message ?? String(err),
+          );
+        }
+      }
+
+      // HMR refresh: keep the temp Vite server alive across HMR cycles and
+      // invalidate its module graph instead of close+recreate. Closing the
+      // temp server during workerd's first post-cold-start module-fetch
+      // window disrupted the main dev server's transport — the user-visible
+      // symptom was a `transport was disconnected, cannot call "fetchModule"`
+      // error on the first urls.tsx edit (workerd's cache was cold, so its
+      // eval was still in flight when our close() ran). Module-graph
+      // invalidation is the architecturally cleaner refresh: same Vite
+      // instance, same transport, fresh source.
+      //
+      // Falls back to close+recreate when neither the env-level nor
+      // server-level moduleGraph exposes invalidateAll() (defensive — Vite
+      // versions / preset configurations may differ in which graph carries
+      // the module-runner cache).
+      async function refreshTempRscEnv(): Promise<any | null> {
+        let tempRscEnv = await getOrCreateTempServer();
+        if (!tempRscEnv) return null;
+
+        // Module-runner cache is on the per-environment graph in Vite 6+;
+        // older / non-environments setups carry it on the server graph.
+        // Try env first, server second.
+        const envGraph = (tempRscEnv as any).moduleGraph;
+        const serverGraph = (prerenderTempServer as any)?.moduleGraph;
+        const target = envGraph?.invalidateAll
+          ? envGraph
+          : serverGraph?.invalidateAll
+            ? serverGraph
+            : null;
+
+        if (!target) {
+          // No invalidate method available — fall back to close+recreate.
+          // This preserves the previous behavior in case a Vite version
+          // doesn't expose invalidateAll on either graph.
+          debugDiscovery?.(
+            "refreshTempRscEnv: invalidateAll unavailable on env+server graphs, falling back to close+recreate",
+          );
+          if (prerenderTempServer) {
+            await prerenderTempServer.close().catch(() => {});
+            prerenderTempServer = null;
+            prerenderNodeRegistry = null;
+          }
+          return await getOrCreateTempServer();
+        }
+
+        debugDiscovery?.(
+          "refreshTempRscEnv: invalidating module graph (%s)",
+          envGraph?.invalidateAll ? "env" : "server",
+        );
+        target.invalidateAll();
+        // Drop the cached registry so importEntryAndRegistry re-reads it
+        // through the now-invalidated module runner.
+        prerenderNodeRegistry = null;
+        // Clear singleton Maps that Vite's moduleGraph invalidation can't
+        // reach (RouterRegistry / HostRouterRegistry). Without this, an
+        // edit that REMOVES a createRouter() call or CHANGES a router id
+        // would leave the old entry in the registry, and discoverRouters
+        // would still emit its routes alongside whatever the new source
+        // declares.
+        await clearTempRegistries(tempRscEnv);
+        await importEntryAndRegistry(tempRscEnv);
+        return tempRscEnv;
+      }
+
       const discover = async () => {
         const discoverStart = performance.now();
         const rscEnv = (server.environments as any)?.rsc;
@@ -415,7 +652,10 @@ export function createRouterDiscoveryPlugin(
           // Cloudflare dev: no module runner available (workerd-based RSC env).
           // Set devServerOrigin so the virtual module can inject __PRERENDER_DEV_URL
           // for on-demand prerender via the /__rsc_prerender endpoint.
-          debugDiscovery?.("dev: no rsc runner (cloudflare path)");
+          debugDiscovery?.(
+            "dev: cloudflare path start, __rscRouterDiscoveryActive=%s",
+            (globalThis as any).__rscRouterDiscoveryActive ?? false,
+          );
           s.devServerOrigin = getDevServerOrigin();
 
           // Create a temp Node.js server to run runtime discovery and generate
@@ -441,7 +681,7 @@ export function createRouterDiscoveryPlugin(
             }
           } catch (err: any) {
             console.warn(
-              `[rsc-router] Cloudflare dev discovery failed: ${err.message}\n${err.stack}`,
+              `[rango] Cloudflare dev discovery failed: ${err.message}\n${err.stack}`,
             );
           }
 
@@ -493,7 +733,7 @@ export function createRouterDiscoveryPlugin(
           );
         } catch (err: any) {
           console.warn(
-            `[rsc-router] Router discovery failed: ${err.message}\n${err.stack}`,
+            `[rango] Router discovery failed: ${err.message}\n${err.stack}`,
           );
         } finally {
           debugDiscovery?.(
@@ -505,10 +745,14 @@ export function createRouterDiscoveryPlugin(
       };
 
       // Schedule after all plugins have finished configureServer.
-      // Store the promise so the virtual module's load hook can await it.
-      s.discoveryDone = new Promise<void>((resolve) => {
-        setTimeout(() => discover().then(resolve, resolve), 0);
-      });
+      // The gate (s.discoveryDone) is reset via beginDiscoveryGate() and
+      // resolved when discover() finishes, so the virtual manifest module's
+      // load() awaits the populated state.
+      beginDiscoveryGate();
+      setTimeout(
+        () => discover().then(resolveDiscoveryGate, resolveDiscoveryGate),
+        0,
+      );
 
       // Dev-mode on-demand prerender endpoint.
       // When workerd hits a prerender route, it fetches this endpoint instead of
@@ -548,20 +792,15 @@ export function createRouterDiscoveryPlugin(
         if (s.mergedRouteTrie && serverMod.setRouteTrie) {
           serverMod.setRouteTrie(s.mergedRouteTrie);
         }
-        if (serverMod.setRouterManifest) {
-          for (const [routerId, manifest] of s.perRouterManifestDataMap) {
-            serverMod.setRouterManifest(routerId, manifest);
-          }
-        }
-        if (serverMod.setRouterTrie) {
-          for (const [routerId, trie] of s.perRouterTrieMap) {
-            serverMod.setRouterTrie(routerId, trie);
-          }
-        }
-        if (serverMod.setRouterPrecomputedEntries) {
-          for (const [routerId, entries] of s.perRouterPrecomputedMap) {
-            serverMod.setRouterPrecomputedEntries(routerId, entries);
-          }
+        const perRouterSetters: Array<[Map<string, any>, string]> = [
+          [s.perRouterManifestDataMap, "setRouterManifest"],
+          [s.perRouterTrieMap, "setRouterTrie"],
+          [s.perRouterPrecomputedMap, "setRouterPrecomputedEntries"],
+        ];
+        for (const [map, fn] of perRouterSetters) {
+          const setter = serverMod[fn];
+          if (typeof setter !== "function") continue;
+          for (const [routerId, value] of map) setter(routerId, value);
         }
       };
 
@@ -604,7 +843,7 @@ export function createRouterDiscoveryPlugin(
             registry = serverMod.RouterRegistry ?? null;
           } catch (err: any) {
             console.warn(
-              `[rsc-router] Dev prerender module refresh failed: ${err.message}`,
+              `[rango] Dev prerender module refresh failed: ${err.message}`,
             );
             res.statusCode = 500;
             res.end(`Prerender handler error: ${err.message}`);
@@ -657,10 +896,9 @@ export function createRouterDiscoveryPlugin(
             if (wantIntercept && result.interceptSegments?.length) {
               payload = {
                 segments: [...result.segments, ...result.interceptSegments],
-                handles: {
-                  ...result.handles,
-                  ...(result.interceptHandles || {}),
-                },
+                // Pre-encoded MERGED handle string from the producer (handles are
+                // Flight-encoded so Promise/ReactNode values survive the wire).
+                handles: result.interceptHandles ?? "",
               };
             } else {
               payload = { segments: result.segments, handles: result.handles };
@@ -669,9 +907,15 @@ export function createRouterDiscoveryPlugin(
             logResult(200, `match ${result.routeName}`);
             return;
           } catch (err: any) {
-            console.warn(
-              `[rsc-router] Dev prerender failed for ${pathname}: ${err.message}`,
-            );
+            // matchForPrerender now re-throws render failures instead of baking
+            // an error page (issue #587). In dev there is no frozen artifact, so
+            // we fall through (404 -> live handler). A `throw new Skip()` is the
+            // expected "skip this URL" signal, not a failure, so it stays quiet.
+            if (err?.name !== "Skip") {
+              console.warn(
+                `[rango] Dev prerender error for ${pathname} (serving live instead): ${err.message}`,
+              );
+            }
           }
         }
 
@@ -720,32 +964,135 @@ export function createRouterDiscoveryPlugin(
 
         // Re-run runtime discovery so factory-generated routes that the
         // static parser cannot see are refreshed after source changes.
-        let runtimeRediscoveryInProgress = false;
+        // The state-machine concerns (queued/pending/gatePending) are
+        // owned by the gate created above (./discovery/gate-state.ts).
+        // Here we provide just the env-specific work.
         const refreshRuntimeDiscovery = async () => {
           const rscEnv = (server.environments as any)?.rsc;
-          if (!rscEnv?.runner || runtimeRediscoveryInProgress) return;
-          runtimeRediscoveryInProgress = true;
-          const hmrStart = performance.now();
+          const hasMainRunner = !!rscEnv?.runner;
+          // Cloudflare HMR has no main RSC runner (workerd is a separate
+          // runtime). When we have a populated runtime manifest from cold
+          // start, we can re-discover via the temp Node runner — the same
+          // mechanism getOrCreateTempServer() uses at startup. Without a
+          // populated manifest there's nothing useful to do, so bail
+          // before involving the gate machine at all.
+          if (!hasMainRunner && s.perRouterManifests.length === 0) return;
+          await gate.runRefreshCycle(async () => {
+            const hmrStart = performance.now();
+            try {
+              if (hasMainRunner) {
+                await timed(debugDiscovery, "hmr discoverRouters", () =>
+                  discoverRouters(s, rscEnv),
+                );
+                timedSync(debugDiscovery, "hmr writeRouteTypesFiles", () =>
+                  writeRouteTypesFiles(s),
+                );
+                await timed(debugDiscovery, "hmr propagateDiscoveryState", () =>
+                  propagateDiscoveryState(rscEnv),
+                );
+              } else {
+                // Cloudflare HMR: invalidate the temp server's RSC module
+                // graph (or close+recreate as a fallback) so the runner
+                // re-reads the freshly edited source. Keeping the same
+                // Vite instance alive avoids disrupting workerd's transport
+                // during the first post-cold-start module-fetch window.
+                const tempRscEnv = await timed(
+                  debugDiscovery,
+                  "hmr refreshTempRscEnv (cloudflare)",
+                  () => refreshTempRscEnv(),
+                );
+                if (!tempRscEnv) {
+                  throw new Error(
+                    "temp runner unavailable for cloudflare HMR rediscovery",
+                  );
+                }
+                await timed(
+                  debugDiscovery,
+                  "hmr discoverRouters (cloudflare)",
+                  () => discoverRouters(s, tempRscEnv),
+                );
+                timedSync(debugDiscovery, "hmr writeRouteTypesFiles", () =>
+                  writeRouteTypesFiles(s),
+                );
+              }
+              if (s.lastDiscoveryError) {
+                debugDiscovery?.(
+                  "hmr: cleared lastDiscoveryError (%s) after successful rediscovery",
+                  s.lastDiscoveryError.message,
+                );
+                s.lastDiscoveryError = null;
+              }
+              // Cloudflare dev: on a successful cycle drop the workerd runner's
+              // cached worker-entry chain so the next request re-evaluates
+              // createRouter() with the new routes. Fired here in the work path
+              // (not the caller's .then()) so a queued follow-up cycle that
+              // succeeds after an earlier failed cycle still reloads:
+              // runRefreshCycle recurses queued work without awaiting it, so the
+              // original call already resolved on the failed cycle. A failed
+              // cycle throws above and never reaches here, so a broken edit
+              // never reloads the worker onto bad source.
+              if (rscEnv && !rscEnv.runner) forceCloudflareWorkerReload(rscEnv);
+            } catch (err: any) {
+              s.lastDiscoveryError = {
+                message: err?.message ?? String(err),
+                at: Date.now(),
+              };
+              console.warn(
+                `[rango] Runtime re-discovery failed: ${err.message}`,
+              );
+              debugDiscovery?.(
+                "hmr: lastDiscoveryError set (%s) — manifest preserved at last-good; recovery mode active (any in-scan source change will trigger rediscovery)",
+                err?.message,
+              );
+            } finally {
+              debugDiscovery?.(
+                "hmr re-discovery done (%sms)",
+                (performance.now() - hmrStart).toFixed(1),
+              );
+            }
+          });
+        };
+
+        // Cloudflare dev only. workerd serves every request through the
+        // runner-worker singleton, which re-resolves the worker entry per
+        // request via runner.import("virtual:cloudflare/worker-entry"). The
+        // route table lives in the user's createRouter() instance, captured
+        // when that entry chain (entry -> router -> urls) was last evaluated
+        // and then cached in the runner's evaluatedModules. The route-file
+        // watcher refreshes discovery + types on the Node side, but the worker
+        // keeps serving the cached (stale) router: route-definition modules
+        // have no import.meta.hot boundary, so Vite never sends the worker an
+        // HMR update for them and the entry chain is never evicted.
+        //
+        // Fix: after discovery completes, (1) invalidate the worker env's
+        // Node-side module graph, then (2) send a full-reload to the worker.
+        // Step (2) alone is insufficient: the full-reload handler clears the
+        // runner's evaluatedModules and re-imports entrypoints, but each
+        // re-import fetches the module back through this Node-side graph, which
+        // still holds the pre-edit transform of urls.tsx — so createRouter()
+        // rebuilds the stale route table and the new route 404s/hits the
+        // catch-all. Invalidating the graph forces a fresh transform on
+        // re-fetch (the same mechanism refreshTempRscEnv uses for discovery),
+        // so the re-import re-runs createRouter() with the new routes. This is
+        // the programmatic equivalent of the dev-server "r + enter" restart,
+        // scoped to the worker environment instead of tearing down the server.
+        const forceCloudflareWorkerReload = (rscEnv: any) => {
+          if (!rscEnv?.hot) return;
           try {
-            await timed(debugDiscovery, "hmr discoverRouters", () =>
-              discoverRouters(s, rscEnv),
-            );
-            timedSync(debugDiscovery, "hmr writeRouteTypesFiles", () =>
-              writeRouteTypesFiles(s),
-            );
-            await timed(debugDiscovery, "hmr propagateDiscoveryState", () =>
-              propagateDiscoveryState(rscEnv),
+            const graph = rscEnv.moduleGraph;
+            if (graph?.invalidateAll) {
+              graph.invalidateAll();
+              debugDiscovery?.("hmr: invalidated workerd rsc module graph");
+            }
+            rscEnv.hot.send({ type: "full-reload" });
+            debugDiscovery?.(
+              "hmr: forced workerd rsc env reload (full-reload)",
             );
           } catch (err: any) {
-            console.warn(
-              `[rsc-router] Runtime re-discovery failed: ${err.message}`,
-            );
-          } finally {
             debugDiscovery?.(
-              "hmr re-discovery done (%sms)",
-              (performance.now() - hmrStart).toFixed(1),
+              "hmr: workerd reload failed: %s",
+              err?.message ?? err,
             );
-            runtimeRediscoveryInProgress = false;
           }
         };
 
@@ -754,27 +1101,49 @@ export function createRouterDiscoveryPlugin(
           routeChangeTimer = setTimeout(() => {
             routeChangeTimer = undefined;
             const regenStart = debugDiscovery ? performance.now() : 0;
+            const rscEnv = (server.environments as any)?.rsc;
+            const skipStaticWrite =
+              !rscEnv?.runner && s.perRouterManifests.length > 0;
             try {
-              writeCombinedRouteTypesWithTracking(s);
-              if (s.perRouterManifests.length > 0) {
-                supplementGenFilesWithRuntimeRoutes(s);
+              // In cloudflare dev with a populated runtime manifest, the
+              // static parser produces a strictly smaller (and actively
+              // wrong) gen file — supplementGenFilesWithRuntimeRoutes can
+              // only restore factory-only prefixes, and apps with mixed
+              // static+factory routes under shared prefixes (cf-stress)
+              // collapse to the 19-route static view. Skip the static
+              // write entirely; runtime rediscovery below will overwrite
+              // the gen file with the authoritative manifest.
+              if (skipStaticWrite) {
+                debugDiscovery?.(
+                  "watcher: skipping static write (cloudflare HMR — runtime rediscovery owns gen file)",
+                );
+              } else {
+                writeCombinedRouteTypesWithTracking(s);
+                if (s.perRouterManifests.length > 0) {
+                  supplementGenFilesWithRuntimeRoutes(s);
+                }
               }
             } catch (err: any) {
-              console.error(
-                `[rsc-router] Route regeneration error: ${err.message}`,
-              );
+              console.error(`[rango] Route regeneration error: ${err.message}`);
             }
             debugDiscovery?.(
               "watcher: regenerated gen files (%sms)",
               (performance.now() - regenStart).toFixed(1),
             );
             // Async: re-run runtime discovery to refresh factory-generated
-            // routes that the static parser cannot resolve.
+            // routes that the static parser cannot resolve. Resolves the
+            // discovery gate when complete.
             if (s.perRouterManifests.length > 0) {
+              // The cloudflare workerd reload fires inside refreshRuntimeDiscovery
+              // on the successful cycle (see forceCloudflareWorkerReload call
+              // there) so queued follow-up cycles also trigger it.
               refreshRuntimeDiscovery().catch((err: any) => {
                 console.warn(
-                  `[rsc-router] Runtime re-discovery error: ${err.message}`,
+                  `[rango] Runtime re-discovery error: ${err.message}`,
                 );
+                // Even on error, unblock the gate so workerd's reload doesn't
+                // hang indefinitely against the previous manifest.
+                resolveDiscoveryGate();
               });
             }
           }, 100);
@@ -787,27 +1156,74 @@ export function createRouterDiscoveryPlugin(
             !filePath.endsWith(".tsx") &&
             !filePath.endsWith(".js") &&
             !filePath.endsWith(".jsx")
-          )
+          ) {
+            if (s.lastDiscoveryError) {
+              debugDiscovery?.(
+                "watcher: skip non-source %s [LASTERR %s]",
+                filePath,
+                s.lastDiscoveryError.message,
+              );
+            }
             return;
+          }
           // Apply scan filter as early-exit before reading file
-          if (s.scanFilter && !s.scanFilter(filePath)) return;
+          if (s.scanFilter && !s.scanFilter(filePath)) {
+            if (s.lastDiscoveryError) {
+              debugDiscovery?.(
+                "watcher: skip scan-filter %s [LASTERR %s]",
+                filePath,
+                s.lastDiscoveryError.message,
+              );
+            }
+            return;
+          }
+          // Recovery mode: when the previous HMR re-discovery failed, the
+          // import graph is incomplete and the manifest is stuck at the
+          // last-good state. The fix may land in a non-route file (e.g. a
+          // helper imported by the router, a missing module being created,
+          // or a "use client" component) that the narrow content sniff
+          // would otherwise filter out. While in recovery, treat any
+          // in-scan source change as a candidate for rediscovery; the
+          // tighter filter resumes once discovery succeeds again.
+          const inRecoveryMode = !!s.lastDiscoveryError;
           try {
             const source = readFileSync(filePath, "utf-8");
             const trimmed = source.trimStart();
-            if (
+            const isUseClient =
               trimmed.startsWith('"use client"') ||
-              trimmed.startsWith("'use client'")
-            )
-              return;
-            const hasUrls = source.includes("urls(");
-            const hasCreateRouter = /\bcreateRouter\s*[<(]/.test(source);
-            if (!hasUrls && !hasCreateRouter) return;
-            debugDiscovery?.(
-              "watcher: %s matches (urls=%s, router=%s)",
-              filePath,
-              hasUrls,
-              hasCreateRouter,
-            );
+              trimmed.startsWith("'use client'");
+            if (!inRecoveryMode && isUseClient) return;
+            // Cheap raw pre-check first; only when a candidate token is present
+            // do we confirm it occurs in real code (not a comment/string) via a
+            // single allocation-free code-region scan. Most saved files contain
+            // neither token and skip the scan entirely. This avoids a comment or
+            // string mention spuriously marking a file relevant and triggering an
+            // unnecessary re-discovery on save.
+            let hasUrls = source.includes("urls(");
+            let hasCreateRouter = /\bcreateRouter\s*[<(]/.test(source);
+            if (hasUrls) hasUrls = firstCodeMatchIndex(source, /urls\(/g) >= 0;
+            if (hasCreateRouter) {
+              hasCreateRouter =
+                firstCodeMatchIndex(source, /\bcreateRouter\s*[<(]/g) >= 0;
+            }
+            if (!inRecoveryMode && !hasUrls && !hasCreateRouter) return;
+            if (inRecoveryMode) {
+              debugDiscovery?.(
+                "watcher: recovery rediscovery for %s (urls=%s, router=%s, useClient=%s) [LASTERR %s]",
+                filePath,
+                hasUrls,
+                hasCreateRouter,
+                isUseClient,
+                s.lastDiscoveryError!.message,
+              );
+            } else {
+              debugDiscovery?.(
+                "watcher: %s matches (urls=%s, router=%s)",
+                filePath,
+                hasUrls,
+                hasCreateRouter,
+              );
+            }
             // Invalidate cache when a router file changes (new router added/removed)
             if (hasCreateRouter) {
               const nestedRouterConflict = findNestedRouterConflict([
@@ -822,8 +1238,27 @@ export function createRouterDiscoveryPlugin(
               }
               s.cachedRouterFiles = undefined;
             }
+            // Note the event in the gate machine IMMEDIATELY (before the
+            // 100ms debounce and any downstream HMR fanout). This sets
+            // both `pendingEvents` (so refresh's finally holds the gate
+            // through the tail window even if no rediscovery is queued)
+            // and resets `discoveryDone` to a fresh pending promise (so
+            // workerd reloads triggered by the same source change can't
+            // observe a stale resolved gate from cold-start). Resolved
+            // by the trailing refreshRuntimeDiscovery() cycle.
+            if (s.perRouterManifests.length > 0) {
+              gate.noteRouteEvent();
+            }
             scheduleRouteRegeneration();
-          } catch {
+          } catch (readErr: any) {
+            if (s.lastDiscoveryError) {
+              debugDiscovery?.(
+                "watcher: read error %s: %s [LASTERR %s]",
+                filePath,
+                readErr?.message,
+                s.lastDiscoveryError.message,
+              );
+            }
             // Ignore read errors for deleted/moved files
           }
         };
@@ -886,7 +1321,7 @@ export function createRouterDiscoveryPlugin(
         const rscEnv = (tempServer.environments as any)?.rsc;
         if (!rscEnv?.runner) {
           console.warn(
-            "[rsc-router] RSC environment runner not available during build, skipping manifest generation",
+            "[rango] RSC environment runner not available during build, skipping manifest generation",
           );
           return;
         }
@@ -929,7 +1364,8 @@ export function createRouterDiscoveryPlugin(
           .filter(Boolean)
           .join("\n");
         throw new Error(
-          `[rsc-router] Build-time router discovery failed:\n${details}`,
+          `[rango] Build-time router discovery failed:\n${details}`,
+          { cause: err },
         );
       } finally {
         delete (globalThis as any).__rscRouterDiscoveryActive;
@@ -946,6 +1382,35 @@ export function createRouterDiscoveryPlugin(
       }
     },
 
+    // Suppress vite's HMR cascade for our own gen-file writes.
+    //
+    // After every cf HMR cycle, refreshTempRscEnv → writeRouteTypesFiles
+    // writes the configured gen files (default `router.named-routes.gen.ts`,
+    // but the source filenames and gen suffix are user-configurable). The
+    // chokidar watcher then fires twice independently: our
+    // `handleRouteFileChange` (already short-circuited by
+    // `consumeSelfGenWrite` inside `maybeHandleGeneratedRouteFileMutation`),
+    // AND vite's own HMR pipeline (which invalidates the gen file's
+    // importers and triggers a second workerd full reload — visible to the
+    // user as a duplicate "[Rango] HMR: version changed" on the client).
+    //
+    // `peekSelfGenWrite` is the authoritative filter: its map only contains
+    // paths that `markSelfGenWrite` has registered, so it natively works
+    // for any configured gen-file name. It is non-consuming so the chokidar
+    // handler that fires later can still consume the same entry. Returning
+    // [] tells vite "no modules invalidated by this change" — safe because
+    // `s.perRouterManifests` is already up-to-date (the write that just
+    // happened is the consequence of our just-completed rediscovery).
+    handleHotUpdate(ctx) {
+      if (peekSelfGenWrite(s, ctx.file)) {
+        debugDiscovery?.(
+          "handleHotUpdate: suppressing self-write HMR cascade for %s",
+          ctx.file,
+        );
+        return [];
+      }
+    },
+
     // Virtual module: provides the pre-generated route manifest as a JS module
     // that calls setCachedManifest() at import time.
     resolveId(id) {
@@ -966,8 +1431,10 @@ export function createRouterDiscoveryPlugin(
         // This is critical for Cloudflare dev where the worker runs in a separate
         // Miniflare process and can only receive manifest data via the virtual module.
         if (s.discoveryDone) {
-          await timed(debugRoutes, "await discoveryDone (manifest)", () =>
-            Promise.resolve(s.discoveryDone),
+          await timed(
+            debugRoutes,
+            "await discoveryDone (manifest)",
+            () => s.discoveryDone,
           );
         }
         const code = await timed(
@@ -983,8 +1450,10 @@ export function createRouterDiscoveryPlugin(
       const perRouterPrefix = "\0" + VIRTUAL_ROUTES_MANIFEST_ID + "/";
       if (id.startsWith(perRouterPrefix)) {
         if (s.discoveryDone) {
-          await timed(debugRoutes, "await discoveryDone (per-router)", () =>
-            Promise.resolve(s.discoveryDone),
+          await timed(
+            debugRoutes,
+            "await discoveryDone (per-router)",
+            () => s.discoveryDone,
           );
         }
         const routerId = id.slice(perRouterPrefix.length);