Merge pull request 'Promote to Production: CAR-1318 frontend image-bump alignment + CAR-1216/CAR-1279 Phase 2' (#294) from uat into main

Promote to Production: CAR-1318 frontend image-bump alignment + CAR-1216/CAR-1279 Phase 2

UAT PASS (Deal Dottie) + Security PASS (Stockboy Steve) on CAR-1320.
Merged by CEO (Coupon Carl) as production gate.

cc @cpfarhood

.gitea/workflows/ci.yml

@@ -72,12 +72,6 @@ jobs:
   lighthouse:
     runs-on: ubuntu-latest
     needs: [test]
-    # CAR-1218: continue-on-error until the Gitea Actions act runner can
-    # reliably capture lhci's stdout (currently suppressed — lhci exits
-    # ~40ms after start with no log output). The job still runs and
-    # reports; failures are surfaced on the PR but no longer block it.
-    # Quality-gate assertions in lighthouserc.json are unchanged.
-    continue-on-error: true
     steps:
       - uses: actions/checkout@34e114876b0b11c390a56381ad16ebd13914f8d5
       - uses: actions/setup-node@49933ea5288caeca8642d1e84afbd3f7d6820020
@@ -92,24 +86,13 @@ jobs:
           npx playwright install --with-deps chromium
       - name: Start preview server
         run: |
-          npx vite preview --host 127.0.0.1 --port 4173 &
-          npx wait-on http://127.0.0.1:4173/ --timeout 30000
+          npm run preview &
+          npx wait-on http://localhost:4173/ --timeout 30000
       - name: Run Lighthouse CI
-        # CAR-1218: act_runner does not honor continue-on-error at the job level
-        # (job still posts 'failure' status). Apply at the step level so the
-        # commit status reflects success and the PR is unblocked. lhci output
-        # is captured to a file (act_runner suppresses stdout from lhci).
-        continue-on-error: true
         run: |
-          {
-            CHROME_PATH=$(find /home/runner/.cache/ms-playwright -name chrome -type f 2>/dev/null | head -1)
-            npm install -g @lhci/cli
-            CHROME_PATH="$CHROME_PATH" lhci autorun --chrome-flags="--headless=new --no-sandbox --disable-gpu --disable-dev-shm-usage"
-          } > /tmp/lhci.log 2>&1 || true
-          echo '=== lhci log (cat /tmp/lhci.log) ==='
-          cat /tmp/lhci.log || echo 'no lhci log produced'
-          echo '=== end lhci log ==='
-          exit 0
+          CHROME_PATH=$(find /home/runner/.cache/ms-playwright -name chrome -type f 2>/dev/null | head -1)
+          npm install -g @lhci/cli
+          CHROME_PATH="$CHROME_PATH" lhci autorun --chrome-flags="--headless=new --no-sandbox --disable-gpu --disable-dev-shm-usage"
 
   build-and-push:
     runs-on: ubuntu-latest
@@ -512,7 +495,7 @@ jobs:
         if: needs.build-and-push.result == 'success'
         run: |
           cd infra/apps/overlays/dev
-          kustomize edit set image ghcr.io/cartsnitch/cartsnitch=git.farh.net/cartsnitch/cartsnitch:${{ steps.frontend_tag.outputs.tag }}
+          kustomize edit set image ghcr.io/cartsnitch/app=git.farh.net/cartsnitch/cartsnitch:${{ steps.frontend_tag.outputs.tag }}
 
       - name: Determine image tag for receiptwitness
         id: receiptwitness_tag
@@ -594,6 +577,16 @@ jobs:
           if [ "${REVIEW_HTTP}" -lt 200 ] || [ "${REVIEW_HTTP}" -ge 300 ]; then
             echo "::notice::Failed to request reviewers for cartsnitch/infra PR #${PR_NUM} (HTTP ${REVIEW_HTTP}); continuing"
           fi
+          # CAR-1216: the in-job merge attempt is a best-effort fast-path only.
+          # `cartsnitch/infra` main requires a human approving review (immutable
+          # branch protection); the CI bot (`CI_GITEA_TOKEN`) can never self-
+          # approve, so this merge call structurally cannot succeed in the
+          # general case. Any non-merged outcome (approvals pending, checks
+          # pending, any other Gitea message) is the GitOps approval gate, not
+          # a CI failure — the PR is already opened and `cs_savannah` is
+          # requested as reviewer above. Surface the response as a notice and
+          # exit success. The only hard-fail (`exit 1`) in this step remains
+          # the empty-`PR_NUM` check (PR could not be created at all).
           MERGE_RESP=$(curl -sS -X POST \
             -H "Authorization: token ${CI_GITEA_TOKEN}" \
             -H "Content-Type: application/json" \
@@ -602,17 +595,9 @@ jobs:
           MERGED=$(echo "$MERGE_RESP" | jq -r '.merged // false')
           if [ "$MERGED" = "true" ]; then
             echo "PR #${PR_NUM} merged into cartsnitch/infra main"
-          elif echo "$MERGE_RESP" | grep -qi 'does not have enough approvals'; then
-            # GitOps approval gate: the PR is correctly opened and surfaces in
-            # the CTO queue via the reviewers request above. Treat as success
-            # (exit 0) so the deploy job does not hard-fail on the approvals
-            # requirement that only a human maintainer can satisfy.
-            echo "::notice::infra PR #${PR_NUM} opened and awaiting CTO (cs_savannah) approve+merge — GitOps approval gate, not a failure"
-            exit 0
           else
-            echo "::error::Auto-merge of cartsnitch/infra PR #${PR_NUM} failed: $MERGE_RESP"
-            echo "::error::Reassign to cs_savannah (authorized merger for cartsnitch/infra main) for backstop merge."
-            exit 1
+            echo "::notice::infra PR #${PR_NUM} opened and awaiting CTO (cs_savannah) approve+merge — GitOps approval gate, not a failure: $MERGE_RESP"
+            exit 0
           fi
 
   deploy-uat:
@@ -656,7 +641,7 @@ jobs:
         if: needs.build-and-push.result == 'success'
         run: |
           cd infra/apps/overlays/uat
-          kustomize edit set image ghcr.io/cartsnitch/cartsnitch=git.farh.net/cartsnitch/cartsnitch:${{ steps.frontend_tag.outputs.tag }}
+          kustomize edit set image ghcr.io/cartsnitch/app=git.farh.net/cartsnitch/cartsnitch:${{ steps.frontend_tag.outputs.tag }}
 
       - name: Determine image tag for receiptwitness
         id: receiptwitness_tag
@@ -738,6 +723,16 @@ jobs:
           if [ "${REVIEW_HTTP}" -lt 200 ] || [ "${REVIEW_HTTP}" -ge 300 ]; then
             echo "::notice::Failed to request reviewers for cartsnitch/infra PR #${PR_NUM} (HTTP ${REVIEW_HTTP}); continuing"
           fi
+          # CAR-1216: the in-job merge attempt is a best-effort fast-path only.
+          # `cartsnitch/infra` main requires a human approving review (immutable
+          # branch protection); the CI bot (`CI_GITEA_TOKEN`) can never self-
+          # approve, so this merge call structurally cannot succeed in the
+          # general case. Any non-merged outcome (approvals pending, checks
+          # pending, any other Gitea message) is the GitOps approval gate, not
+          # a CI failure — the PR is already opened and `cs_savannah` is
+          # requested as reviewer above. Surface the response as a notice and
+          # exit success. The only hard-fail (`exit 1`) in this step remains
+          # the empty-`PR_NUM` check (PR could not be created at all).
           MERGE_RESP=$(curl -sS -X POST \
             -H "Authorization: token ${CI_GITEA_TOKEN}" \
             -H "Content-Type: application/json" \
@@ -746,15 +741,7 @@ jobs:
           MERGED=$(echo "$MERGE_RESP" | jq -r '.merged // false')
           if [ "$MERGED" = "true" ]; then
             echo "PR #${PR_NUM} merged into cartsnitch/infra main"
-          elif echo "$MERGE_RESP" | grep -qi 'does not have enough approvals'; then
-            # GitOps approval gate: the PR is correctly opened and surfaces in
-            # the CTO queue via the reviewers request above. Treat as success
-            # (exit 0) so the deploy job does not hard-fail on the approvals
-            # requirement that only a human maintainer can satisfy.
-            echo "::notice::infra PR #${PR_NUM} opened and awaiting CTO (cs_savannah) approve+merge — GitOps approval gate, not a failure"
-            exit 0
           else
-            echo "::error::Auto-merge of cartsnitch/infra PR #${PR_NUM} failed: $MERGE_RESP"
-            echo "::error::Reassign to cs_savannah (authorized merger for cartsnitch/infra main) for backstop merge."
-            exit 1
+            echo "::notice::infra PR #${PR_NUM} opened and awaiting CTO (cs_savannah) approve+merge — GitOps approval gate, not a failure: $MERGE_RESP"
+            exit 0
           fi

auth/Dockerfile

@@ -1,4 +1,4 @@
-FROM node:22-alpine AS builder
+FROM node:22-alpine@sha256:8ea2348b068a9544dae7317b4f3aafcdc032df1647bb7d768a05a5cad1a7683f AS builder
 RUN apk update && apk upgrade --no-cache
 WORKDIR /app
 COPY package.json package-lock.json* ./
@@ -7,7 +7,7 @@ COPY tsconfig.json ./
 COPY src/ src/
 RUN npm run build
 
-FROM node:22-alpine
+FROM node:22-alpine@sha256:8ea2348b068a9544dae7317b4f3aafcdc032df1647bb7d768a05a5cad1a7683f
 RUN apk update && apk upgrade --no-cache
 WORKDIR /app
 ENV NODE_ENV=production

auth/src/__tests__/health.test.ts

@@ -19,9 +19,18 @@ describe('Auth health endpoint', () => {
             }
             res.writeHead(200, { 'Content-Type': 'application/json' });
             res.end(JSON.stringify({ status: 'ok', db: 'reachable' }));
-          } catch {
+          } catch (err) {
+            // Mirror src/index.ts: log the error and include the message in the
+            // response body so /health 503s are diagnosable from pod logs.
+            console.error(
+              '[auth /health] DB probe failed:',
+              err instanceof Error ? `${err.name}: ${err.message}` : err,
+            );
+            const detail = err instanceof Error ? err.message : 'unknown error';
             res.writeHead(503, { 'Content-Type': 'application/json' });
-            res.end(JSON.stringify({ status: 'error', db: 'unreachable' }));
+            res.end(
+              JSON.stringify({ status: 'error', db: 'unreachable', error: detail }),
+            );
           }
           return;
         }
@@ -76,7 +85,10 @@ describe('Auth health endpoint', () => {
     close();
 
     equal(status, 503);
-    equal(body, '{"status":"error","db":"unreachable"}');
+    const parsed = JSON.parse(body);
+    equal(parsed.status, 'error');
+    equal(parsed.db, 'unreachable');
+    equal(parsed.error, 'connection refused');
   });
 
   it('returns 503 with db=unreachable when query times out', async () => {
@@ -95,7 +107,14 @@ describe('Auth health endpoint', () => {
     close();
 
     equal(status, 503);
-    equal(body, '{"status":"error","db":"unreachable"}');
+    const parsed = JSON.parse(body);
+    equal(parsed.status, 'error');
+    equal(parsed.db, 'unreachable');
+    // The query promise rejects with a synthetic 'timeout' error; the
+    // Promise.race wrapper also rejects with 'DB timeout'. The body should
+    // surface whichever error was thrown — accept either to stay robust.
+    equal(typeof parsed.error, 'string');
+    equal(parsed.error.length > 0, true);
   });
 
   it('returns a terminal response for unknown paths (no hang)', async () => {

auth/src/index.ts

@@ -21,9 +21,19 @@ const server = createServer(async (req, res) => {
       }
       res.writeHead(200, { "Content-Type": "application/json" });
       res.end(JSON.stringify({ status: "ok", db: "reachable" }));
-    } catch {
+    } catch (err) {
+      // Log the actual error so /health 503s are diagnosable from pod logs
+      // (CAR-1276: UAT auth was crashlooping with no log output beyond the
+      // initial "listening on port 3001" line because this catch was empty).
+      console.error(
+        "[auth /health] DB probe failed:",
+        err instanceof Error ? `${err.name}: ${err.message}` : err,
+      );
+      const detail = err instanceof Error ? err.message : "unknown error";
       res.writeHead(503, { "Content-Type": "application/json" });
-      res.end(JSON.stringify({ status: "error", db: "unreachable" }));
+      res.end(
+        JSON.stringify({ status: "error", db: "unreachable", error: detail }),
+      );
     }
     return;
   }

lighthouserc.json

@@ -2,7 +2,7 @@
   "ci": {
     "collect": {
       "staticDistDir": "./dist",
-      "url": ["http://127.0.0.1:4173/"],
+      "url": ["http://localhost:4173/"],
       "numberOfRuns": 1,
       "settings": {
         "chromeFlags": ["--headless=new", "--no-sandbox", "--disable-gpu", "--disable-dev-shm-usage"],