fix: clear EXIT trap before return to avoid unbound $tmpdir under set -u

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

bin/disinto

@@ -12,6 +12,7 @@
 #   disinto secrets <subcommand>        Manage encrypted secrets
 #   disinto run <action-id>              Run action in ephemeral runner container
 #   disinto ci-logs <pipeline> [--step <name>]  Read CI logs from Woodpecker SQLite
+#   disinto backup create <outfile>     Export factory state for migration
 #
 # Usage:
 #   disinto init https://github.com/user/repo
@@ -39,6 +40,7 @@ source "${FACTORY_ROOT}/lib/generators.sh"
 source "${FACTORY_ROOT}/lib/forge-push.sh"
 source "${FACTORY_ROOT}/lib/ci-setup.sh"
 source "${FACTORY_ROOT}/lib/release.sh"
+source "${FACTORY_ROOT}/lib/backup.sh"
 source "${FACTORY_ROOT}/lib/claude-config.sh"
 
 # ── Helpers ──────────────────────────────────────────────────────────────────
@@ -62,6 +64,7 @@ Usage:
   disinto hire-an-agent <agent-name> <role> [--formula <path>] [--local-model <url>] [--model <name>]
                                      Hire a new agent (create user + .profile repo; re-run to rotate credentials)
   disinto agent <subcommand>           Manage agent state (enable/disable)
+  disinto backup create <outfile>      Export factory state (issues + ops bundle)
   disinto edge <verb> [options]        Manage edge tunnel registrations
 
 Edge subcommands:
@@ -2893,6 +2896,23 @@ EOF
   esac
 }
 
+# ── backup command ────────────────────────────────────────────────────────────
+# Usage: disinto backup create <outfile.tar.gz>
+disinto_backup() {
+  local subcmd="${1:-}"
+  shift || true
+
+  case "$subcmd" in
+    create)
+      backup_create "$@"
+      ;;
+    *)
+      echo "Usage: disinto backup create <outfile.tar.gz>" >&2
+      exit 1
+      ;;
+  esac
+}
+
 # ── Main dispatch ────────────────────────────────────────────────────────────
 
 case "${1:-}" in
@@ -2909,6 +2929,7 @@ case "${1:-}" in
   hire-an-agent)   shift; disinto_hire_an_agent "$@" ;;
   agent)           shift; disinto_agent "$@" ;;
   edge)            shift; disinto_edge "$@" ;;
+  backup)          shift; disinto_backup "$@" ;;
   -h|--help)       usage ;;
   *)               usage ;;
 esac

lib/agent-sdk.sh

@@ -52,8 +52,9 @@ claude_run_with_watchdog() {
   out_file=$(mktemp) || return 1
   trap 'rm -f "$out_file"' RETURN
 
-  # Start claude in background, capturing stdout to temp file
+  # Start claude in new process group (setsid creates new session, $pid is PGID leader)
-  "${cmd[@]}" > "$out_file" 2>>"$LOGFILE" &
+  # All children of claude will inherit this process group
+  setsid "${cmd[@]}" > "$out_file" 2>>"$LOGFILE" &
   pid=$!
 
   # Background watchdog: poll for final result marker
@@ -84,12 +85,12 @@ claude_run_with_watchdog() {
       sleep "$grace"
       if kill -0 "$pid" 2>/dev/null; then
         log "watchdog: claude -p idle for ${grace}s after final result; SIGTERM"
-        kill -TERM "$pid" 2>/dev/null || true
+        kill -TERM -- "-$pid" 2>/dev/null || true
         # Give it a moment to clean up
         sleep 5
         if kill -0 "$pid" 2>/dev/null; then
           log "watchdog: force kill after SIGTERM timeout"
-          kill -KILL "$pid" 2>/dev/null || true
+          kill -KILL -- "-$pid" 2>/dev/null || true
         fi
       fi
     fi
@@ -100,16 +101,16 @@ claude_run_with_watchdog() {
   timeout --foreground "${CLAUDE_TIMEOUT:-7200}" tail --pid="$pid" -f /dev/null 2>/dev/null
   rc=$?
 
-  # Clean up the watchdog
+  # Clean up the watchdog (target process group if it spawned children)
-  kill "$grace_pid" 2>/dev/null || true
+  kill -- "-$grace_pid" 2>/dev/null || true
   wait "$grace_pid" 2>/dev/null || true
 
-  # When timeout fires (rc=124), explicitly kill the orphaned claude process
+  # When timeout fires (rc=124), explicitly kill the orphaned claude process group
   # tail --pid is a passive waiter, not a supervisor
   if [ "$rc" -eq 124 ]; then
-    kill "$pid" 2>/dev/null || true
+    kill -TERM -- "-$pid" 2>/dev/null || true
     sleep 1
-    kill -KILL "$pid" 2>/dev/null || true
+    kill -KILL -- "-$pid" 2>/dev/null || true
   fi
 
   # Output the captured stdout

lib/backup.sh

@@ -0,0 +1,136 @@
+#!/usr/bin/env bash
+# =============================================================================
+# disinto backup — export factory state for migration
+#
+# Usage: source this file, then call backup_create <outfile.tar.gz>
+# Requires: FORGE_URL, FORGE_TOKEN, FORGE_REPO, FORGE_OPS_REPO, OPS_REPO_ROOT
+# =============================================================================
+set -euo pipefail
+
+# Fetch all issues (open + closed) for a repo slug and emit the normalized JSON array.
+# Usage: _backup_fetch_issues <org/repo>
+_backup_fetch_issues() {
+  local repo_slug="$1"
+  local api_url="${FORGE_API_BASE}/repos/${repo_slug}"
+
+  local all_issues="[]"
+  for state in open closed; do
+    local page=1
+    while true; do
+      local page_items
+      page_items=$(curl -sf -X GET \
+        -H "Authorization: token ${FORGE_TOKEN}" \
+        -H "Content-Type: application/json" \
+        "${api_url}/issues?state=${state}&type=issues&limit=50&page=${page}") || {
+        echo "ERROR: failed to fetch ${state} issues from ${repo_slug} (page ${page})" >&2
+        return 1
+      }
+      local count
+      count=$(printf '%s' "$page_items" | jq 'length' 2>/dev/null) || count=0
+      [ -z "$count" ] && count=0
+      [ "$count" -eq 0 ] && break
+      all_issues=$(printf '%s\n%s' "$all_issues" "$page_items" | jq -s 'add')
+      [ "$count" -lt 50 ] && break
+      page=$((page + 1))
+    done
+  done
+
+  # Normalize to the schema: number, title, body, labels, state
+  printf '%s' "$all_issues" | jq '[.[] | {
+    number: .number,
+    title: .title,
+    body: .body,
+    labels: [.labels[]?.name],
+    state: .state
+  }] | sort_by(.number)'
+}
+
+# Create a backup tarball of factory state.
+# Usage: backup_create <outfile.tar.gz>
+backup_create() {
+  local outfile="${1:-}"
+  if [ -z "$outfile" ]; then
+    echo "Error: output file required" >&2
+    echo "Usage: disinto backup create <outfile.tar.gz>" >&2
+    return 1
+  fi
+
+  # Resolve to absolute path before cd-ing into tmpdir
+  case "$outfile" in
+    /*) ;;
+    *) outfile="$(pwd)/${outfile}" ;;
+  esac
+
+  # Validate required env
+  : "${FORGE_URL:?FORGE_URL must be set}"
+  : "${FORGE_TOKEN:?FORGE_TOKEN must be set}"
+  : "${FORGE_REPO:?FORGE_REPO must be set}"
+
+  local forge_ops_repo="${FORGE_OPS_REPO:-${FORGE_REPO}-ops}"
+  local ops_repo_root="${OPS_REPO_ROOT:-}"
+
+  if [ -z "$ops_repo_root" ] || [ ! -d "$ops_repo_root/.git" ]; then
+    echo "Error: OPS_REPO_ROOT (${ops_repo_root:-<unset>}) is not a valid git repo" >&2
+    return 1
+  fi
+
+  local tmpdir
+  tmpdir=$(mktemp -d)
+  trap 'rm -rf "$tmpdir"' EXIT
+
+  local project_name="${FORGE_REPO##*/}"
+
+  echo "=== disinto backup create ==="
+  echo "Forge: ${FORGE_URL}"
+  echo "Repos: ${FORGE_REPO}, ${forge_ops_repo}"
+
+  # ── 1. Export issues ──────────────────────────────────────────────────────
+  mkdir -p "${tmpdir}/issues"
+
+  echo "Fetching issues for ${FORGE_REPO}..."
+  _backup_fetch_issues "$FORGE_REPO" > "${tmpdir}/issues/${project_name}.json"
+  local main_count
+  main_count=$(jq 'length' "${tmpdir}/issues/${project_name}.json")
+  echo "  ${main_count} issues exported"
+
+  echo "Fetching issues for ${forge_ops_repo}..."
+  _backup_fetch_issues "$forge_ops_repo" > "${tmpdir}/issues/${project_name}-ops.json"
+  local ops_count
+  ops_count=$(jq 'length' "${tmpdir}/issues/${project_name}-ops.json")
+  echo "  ${ops_count} issues exported"
+
+  # ── 2. Git bundle of ops repo ────────────────────────────────────────────
+  mkdir -p "${tmpdir}/repos"
+
+  echo "Creating git bundle for ${forge_ops_repo}..."
+  git -C "$ops_repo_root" bundle create "${tmpdir}/repos/${project_name}-ops.bundle" --all 2>&1
+  echo "  bundle created ($(du -h "${tmpdir}/repos/${project_name}-ops.bundle" | cut -f1))"
+
+  # ── 3. Metadata ──────────────────────────────────────────────────────────
+  local created_at
+  created_at=$(date -u +"%Y-%m-%dT%H:%M:%SZ")
+
+  jq -n \
+    --arg created_at "$created_at" \
+    --arg source_host "$(hostname)" \
+    --argjson schema_version 1 \
+    --arg forgejo_url "$FORGE_URL" \
+    '{
+      created_at: $created_at,
+      source_host: $source_host,
+      schema_version: $schema_version,
+      forgejo_url: $forgejo_url
+    }' > "${tmpdir}/metadata.json"
+
+  # ── 4. Pack tarball ──────────────────────────────────────────────────────
+  echo "Creating tarball: ${outfile}"
+  tar -czf "$outfile" -C "$tmpdir" metadata.json issues repos
+  local size
+  size=$(du -h "$outfile" | cut -f1)
+  echo "=== Backup complete: ${outfile} (${size}) ==="
+
+  # Clean up before returning — the EXIT trap references the local $tmpdir
+  # which goes out of scope after return, causing 'unbound variable' under set -u.
+  trap - EXIT
+  rm -rf "$tmpdir"
+}

lib/generators.sh

@@ -405,6 +405,9 @@ services:
       WOODPECKER_SERVER: localhost:9000
       WOODPECKER_AGENT_SECRET: ${WOODPECKER_AGENT_SECRET:-}
       WOODPECKER_GRPC_SECURE: "false"
+      WOODPECKER_GRPC_KEEPALIVE_TIME: "10s"
+      WOODPECKER_GRPC_KEEPALIVE_TIMEOUT: "20s"
+      WOODPECKER_GRPC_KEEPALIVE_PERMIT_WITHOUT_CALLS: "true"
       WOODPECKER_HEALTHCHECK_ADDR: ":3333"
       WOODPECKER_BACKEND_DOCKER_NETWORK: ${WOODPECKER_CI_NETWORK:-disinto_disinto-net}
       WOODPECKER_MAX_WORKFLOWS: 1

nomad/jobs/woodpecker-agent.hcl

@@ -57,7 +57,7 @@ job "woodpecker-agent" {
       check {
         type     = "http"
         path     = "/healthz"
-        interval = "15s"
+        interval = "10s"
         timeout  = "3s"
       }
     }
@@ -89,10 +89,13 @@ job "woodpecker-agent" {
       # Nomad's port stanza to the allocation's IP (not localhost), so the
       # agent must use the LXC's eth0 IP, not 127.0.0.1.
       env {
-        WOODPECKER_SERVER         = "${attr.unique.network.ip-address}:9000"
+        WOODPECKER_SERVER                   = "${attr.unique.network.ip-address}:9000"
-        WOODPECKER_GRPC_SECURE    = "false"
+        WOODPECKER_GRPC_SECURE              = "false"
-        WOODPECKER_MAX_WORKFLOWS  = "1"
+        WOODPECKER_GRPC_KEEPALIVE_TIME      = "10s"
-        WOODPECKER_HEALTHCHECK_ADDR = ":3333"
+        WOODPECKER_GRPC_KEEPALIVE_TIMEOUT   = "20s"
+        WOODPECKER_GRPC_KEEPALIVE_PERMIT_WITHOUT_CALLS = "true"
+        WOODPECKER_MAX_WORKFLOWS            = "1"
+        WOODPECKER_HEALTHCHECK_ADDR         = ":3333"
       }
 
       # ── Vault-templated agent secret ──────────────────────────────────

review/review-pr.sh

@@ -52,8 +52,35 @@ REVIEW_TMPDIR=$(mktemp -d)
 
 log() { printf '[%s] PR#%s %s\n' "$(date -u '+%Y-%m-%d %H:%M:%S UTC')" "$PR_NUMBER" "$*" >> "$LOGFILE"; }
 status() { printf '[%s] PR #%s: %s\n' "$(date -u '+%Y-%m-%d %H:%M:%S UTC')" "$PR_NUMBER" "$*" > "$STATUSFILE"; log "$*"; }
-cleanup() { rm -rf "$REVIEW_TMPDIR" "$LOCKFILE" "$STATUSFILE" "/tmp/${PROJECT_NAME}-review-graph-${PR_NUMBER}.json"; }
+
-trap cleanup EXIT
+# cleanup — remove temp files (NOT lockfile — cleanup_on_exit handles that)
+cleanup() {
+  rm -rf "$REVIEW_TMPDIR" "$STATUSFILE" "/tmp/${PROJECT_NAME}-review-graph-${PR_NUMBER}.json"
+}
+
+# cleanup_on_exit — defensive cleanup: remove lockfile if we own it, kill residual children
+# This handles the case where review-pr.sh is terminated unexpectedly (e.g., watchdog SIGTERM)
+cleanup_on_exit() {
+  local ec=$?
+  # Remove lockfile only if we own it (PID matches $$)
+  if [ -f "$LOCKFILE" ] && [ -n "$(cat "$LOCKFILE" 2>/dev/null)" ]; then
+    if [ "$(cat "$LOCKFILE" 2>/dev/null)" = "$$" ]; then
+      rm -f "$LOCKFILE"
+      log "cleanup_on_exit: removed lockfile (we owned it)"
+    fi
+  fi
+  # Kill any direct children that may have been spawned by this process
+  # (e.g., bash -c commands from Claude's Bash tool that didn't get reaped)
+  pkill -P $$ 2>/dev/null || true
+  # Call the main cleanup function to remove temp files
+  cleanup
+  exit "$ec"
+}
+trap cleanup_on_exit EXIT INT TERM
+
+# Note: EXIT trap is already set above. The cleanup function is still available for
+# non-error exits (e.g., normal completion via exit 0 after verdict posted).
+# When review succeeds, we want to skip lockfile removal since the verdict was posted.
 
 # =============================================================================
 # LOG ROTATION
@@ -104,6 +131,7 @@ if [ "$PR_STATE" != "open" ]; then
   log "SKIP: state=${PR_STATE}"
   worktree_cleanup "$WORKTREE"
   rm -f "$OUTPUT_FILE" "$SID_FILE" 2>/dev/null || true
+  rm -f "$LOCKFILE"
   exit 0
 fi
 
@@ -113,7 +141,7 @@ fi
 CI_STATE=$(ci_commit_status "$PR_SHA")
 CI_NOTE=""
 if ! ci_passed "$CI_STATE"; then
-  ci_required_for_pr "$PR_NUMBER" && { log "SKIP: CI=${CI_STATE}"; exit 0; }
+  ci_required_for_pr "$PR_NUMBER" && { log "SKIP: CI=${CI_STATE}"; rm -f "$LOCKFILE"; exit 0; }
   CI_NOTE=" (not required — non-code PR)"
 fi
 
@@ -123,10 +151,10 @@ fi
 ALL_COMMENTS=$(forge_api_all "/issues/${PR_NUMBER}/comments")
 HAS_CMT=$(printf '%s' "$ALL_COMMENTS" | jq --arg s "$PR_SHA" \
   '[.[]|select(.body|contains("<!-- reviewed: "+$s+" -->"))]|length')
-[ "${HAS_CMT:-0}" -gt 0 ] && [ "$FORCE" != "--force" ] && { log "SKIP: reviewed ${PR_SHA:0:7}"; exit 0; }
+[ "${HAS_CMT:-0}" -gt 0 ] && [ "$FORCE" != "--force" ] && { log "SKIP: reviewed ${PR_SHA:0:7}"; rm -f "$LOCKFILE"; exit 0; }
 HAS_FML=$(forge_api_all "/pulls/${PR_NUMBER}/reviews" | jq --arg s "$PR_SHA" \
   '[.[]|select(.commit_id==$s)|select(.state!="COMMENT")]|length')
-[ "${HAS_FML:-0}" -gt 0 ] && [ "$FORCE" != "--force" ] && { log "SKIP: formal review"; exit 0; }
+[ "${HAS_FML:-0}" -gt 0 ] && [ "$FORCE" != "--force" ] && { log "SKIP: formal review"; rm -f "$LOCKFILE"; exit 0; }
 
 # =============================================================================
 # RE-REVIEW DETECTION
@@ -324,3 +352,7 @@ esac
 profile_write_journal "review-${PR_NUMBER}" "Review PR #${PR_NUMBER} (${VERDICT})" "${VERDICT,,}" "" || true
 
 log "DONE: ${VERDICT} (re-review: ${IS_RE_REVIEW})"
+
+# Remove lockfile on successful completion (cleanup_on_exit will also do this,
+# but we do it here to avoid the trap running twice)
+rm -f "$LOCKFILE"

tests/test-watchdog-process-group.sh

@@ -0,0 +1,129 @@
+#!/usr/bin/env bash
+# test-watchdog-process-group.sh — Test that claude_run_with_watchdog kills orphan children
+#
+# This test verifies that when claude_run_with_watchdog terminates the Claude process,
+# all child processes (including those spawned by Claude's Bash tool) are also killed.
+#
+# Reproducer scenario:
+#   1. Create a fake "claude" stub that:
+#      a. Spawns a long-running child process (sleep 3600)
+#      b. Writes a result marker to stdout to trigger idle detection
+#      c. Stays running
+#   2. Run claude_run_with_watchdog with the stub
+#   3. Before the fix: sleep child survives (orphaned to PID 1)
+#   4. After the fix: sleep child dies (killed as part of process group with -PID)
+#
+# Usage: ./tests/test-watchdog-process-group.sh
+
+set -euo pipefail
+
+SCRIPT_DIR="$(cd "$(dirname "$0")/.." && pwd)"
+TEST_TMP="/tmp/test-watchdog-$$"
+LOGFILE="${TEST_TMP}/log.txt"
+PASS=true
+
+# shellcheck disable=SC2317
+cleanup_test() {
+  rm -rf "$TEST_TMP"
+}
+trap cleanup_test EXIT INT TERM
+
+mkdir -p "$TEST_TMP"
+
+log() {
+  printf '[TEST] %s\n' "$*" | tee -a "$LOGFILE"
+}
+
+fail() {
+  printf '[TEST] FAIL: %s\n' "$*" | tee -a "$LOGFILE"
+  PASS=false
+}
+
+pass() {
+  printf '[TEST] PASS: %s\n' "$*" | tee -a "$LOGFILE"
+}
+
+# Export required environment variables
+export CLAUDE_TIMEOUT=10       # Short timeout for testing
+export CLAUDE_IDLE_GRACE=2     # Short grace period for testing
+export LOGFILE="${LOGFILE}"    # Required by agent-sdk.sh
+
+# Create a fake claude stub that:
+# 1. Spawns a long-running child process (sleep 3600) that will become an orphan if parent is killed
+# 2. Writes a result marker to stdout (to trigger the watchdog's idle-after-result path)
+# 3. Stays running so the watchdog can kill it
+cat > "${TEST_TMP}/fake-claude" << 'FAKE_CLAUDE_EOF'
+#!/usr/bin/env bash
+# Fake claude that spawns a child and stays running
+# Simulates Claude's behavior when it spawns a Bash tool command
+
+# Write result marker to stdout (triggers watchdog idle detection)
+echo '{"type":"result","session_id":"test-session-123","verdict":"APPROVE"}'
+
+# Spawn a child that simulates Claude's Bash tool hanging
+# This is the process that should be killed when the parent is terminated
+sleep 3600 &
+CHILD_PID=$!
+
+# Log the child PID for debugging
+echo "FAKE_CLAUDE_CHILD_PID=$CHILD_PID" >&2
+
+# Stay running - sleep in a loop so the watchdog can kill us
+while true; do
+  sleep 3600 &
+  wait $! 2>/dev/null || true
+done
+FAKE_CLAUDE_EOF
+chmod +x "${TEST_TMP}/fake-claude"
+
+log "Testing claude_run_with_watchdog process group cleanup..."
+
+# Source the library and run claude_run_with_watchdog
+cd "$SCRIPT_DIR"
+source lib/agent-sdk.sh
+
+log "Starting claude_run_with_watchdog with fake claude..."
+
+# Run the function directly (not as a script)
+# We need to capture output and redirect stderr
+OUTPUT_FILE="${TEST_TMP}/output.txt"
+timeout 35 bash -c "
+  source '${SCRIPT_DIR}/lib/agent-sdk.sh'
+  CLAUDE_TIMEOUT=10 CLAUDE_IDLE_GRACE=2 LOGFILE='${LOGFILE}' claude_run_with_watchdog '${TEST_TMP}/fake-claude' > '${OUTPUT_FILE}' 2>&1
+  exit \$?
+" || true
+
+# Give the watchdog a moment to clean up
+log "Waiting for cleanup..."
+sleep 5
+
+# More precise check: look for sleep 3600 processes
+# These would be the orphans from our fake claude
+ORPHAN_COUNT=$(pgrep -a sleep 2>/dev/null | grep -c "sleep 3600" 2>/dev/null || echo "0")
+
+if [ "$ORPHAN_COUNT" -gt 0 ]; then
+  log "Found $ORPHAN_COUNT orphan sleep 3600 processes:"
+  pgrep -a sleep | grep "sleep 3600"
+  fail "Orphan children found - process group cleanup did not work"
+else
+  pass "No orphan children found - process group cleanup worked"
+fi
+
+# Also verify that the fake claude itself is not running
+FAKE_CLAUDE_COUNT=$(pgrep -c -f "fake-claude" 2>/dev/null || echo "0")
+if [ "$FAKE_CLAUDE_COUNT" -gt 0 ]; then
+  log "Found $FAKE_CLAUDE_COUNT fake-claude processes still running"
+  fail "Fake claude process(es) still running"
+else
+  pass "Fake claude process terminated"
+fi
+
+# Summary
+echo ""
+if [ "$PASS" = true ]; then
+  log "All tests passed!"
+  exit 0
+else
+  log "Some tests failed. See log at $LOGFILE"
+  exit 1
+fi