ci: trigger CI run for ignore-error=true cache-to fix

Gitea OCI registry sporadically rejects cache blob writes with
"error writing layer blob: unknown" — this fails the build step
even though the image itself was pushed successfully. Adding
ignore-error=true makes cache write failures non-fatal so the
build proceeds regardless of registry-side cache issues.

Fixes recurring CI failure on Build and push Seed image step.

UAT_PLAYBOOK.md

@@ -108,6 +108,11 @@ Expected: one row, `role = 'groomer'`. If zero rows return, the request hit the
 | TC-API-1.24 | Complete setup creates super user | POST /api/setup with business name (after TC-API-1.23) | First user becomes super user, setup completes | Setup errors, 403 on admin endpoints |
 | TC-API-1.25 | Super user accesses admin features | After TC-API-1.24, GET /api/staff/me and verify isSuperUser: true | isSuperUser: true, admin endpoints accessible | 403 on admin, isSuperUser: false |
 | TC-API-1.26 | Auto-provision skipped during OOBE | During fresh setup (needsSetup: true), complete OIDC login — verify no duplicate staff record created before setup completes | No duplicate staff, OOBE completes successfully | Duplicate staff record, 403 before setup, auto-provision interferes with OOBE |
+| TC-API-1.27 | Multi-origin CORS — demo host sign-in | `POST /api/auth/sign-in/social` with `callbackURL=https://demo.groombook.dev` | 200 OK, no origin-mismatch error | 400/403 "Origin mismatch" |
+| TC-API-1.28 | Multi-origin CORS — farh.net host sign-in | `POST /api/auth/sign-in/social` with `callbackURL=https://groombook.farh.net` | 200 OK, no origin-mismatch error | 400/403 "Origin mismatch" |
+| TC-API-1.29 | CORS — untrusted origin blocked (GRO-2586) | POST /api/auth/sign-in/social with `Origin: https://evil.example.com` header | Response has **no** `Access-Control-Allow-Origin` header — attacker origin is not reflected | `Access-Control-Allow-Origin: https://evil.example.com` present in response |
+| TC-API-1.30 | CORS — trusted origin allowed (GRO-2586) | POST /api/auth/sign-in/social with `Origin: https://uat.groombook.dev` header | `Access-Control-Allow-Origin: https://uat.groombook.dev` + `Access-Control-Allow-Credentials: true` | CORS header absent or trusted origin rejected |
+| TC-API-1.31 | CORS — untrusted preflight blocked (GRO-2586) | `curl -i -X OPTIONS https://uat.groombook.dev/api/auth/sign-in/social -H 'Origin: https://evil.example.com' -H 'Access-Control-Request-Method: POST'` | Response has **no** `Access-Control-Allow-Origin: https://evil.example.com` | Preflight reflects attacker origin |
 
 ### 4.2 Client Management
 
@@ -434,6 +439,22 @@ Both use the stops' stored `latitude`/`longitude` in `stopOrder`: **origin = fir
 | TC-API-18.10 | Groomer cannot export another's route | As groomer, export a route owned by a different groomer | 403 Forbidden (`groomers may only access their own route`) |
 | TC-API-18.11 | Receptionist denied | As **receptionist**, export any route | 403 Forbidden (role not permitted) |
 
+
+### 4.19 Boot Resilience — ECONNRESET Recovery (GRO-2652)
+
+Verifies the API process does not crash on transient boot-time DB connection resets and that auth routes degrade gracefully until initialization succeeds.
+
+| TC | Test Case | Steps | Expected Result |
+|----|-----------|-------|-----------------|
+| TC-API-19.1 | Health endpoint available before auth init | 1. Deploy the image (or restart the api pod)<br>2. `GET /health` immediately (within first 2 s of pod start) | 200 `{"status":"ok"}` — server accepts requests before `initAuth()` completes |
+| TC-API-19.2 | Auth routes return 503 when auth not yet initialized | 1. Temporarily set `OIDC_ISSUER` to an unreachable host so `initAuth()` keeps retrying<br>2. `POST /api/auth/sign-in/email` during the retry window | 503 `{"error":"Authentication not configured"}` — process stays alive, does not exit |
+| TC-API-19.3 | Pod does not crash on first-attempt DB reset | 1. Review pod restart count after normal deployment<br>2. Confirm `kubectl get pod -n groombook` shows `RESTARTS: 0` (or same as before deploy) for the new pod | No new restarts — ECONNRESET causes retry, not process exit |
+| TC-API-19.4 | DB query retry log lines visible | After deploy, `kubectl logs -n groombook <api-pod>` | If any DB retry occurred, log lines matching `[auth] DB query attempt N failed` are present; on clean boot no retry lines appear |
+| TC-API-19.5 | Auth init retry log lines visible | When auth init fails and retries, check pod logs | Log lines matching `[auth] initAuth attempt N failed` present; process continues; no `process.exit` |
+| TC-API-19.6 | Auth succeeds after transient DB hiccup | 1. Allow pod to retry until DB is available<br>2. `POST /api/auth/sign-in/email` with valid credentials after init succeeds | 200 with session cookie — auth recovers without pod restart |
+| TC-API-19.7 | Normal sign-in still works end-to-end | Follow TC-WEB-SSO-3 (SSO sign-in) on UAT | Successful sign-in, staff list visible — no regression from resilience changes |
+| TC-API-19.8 | Public routes unaffected during auth retry | While auth is retrying (TC-API-19.2 setup), `GET /api/branding` | 200 with branding data — public routes bypass auth and serve normally |
+
 ## Pass/Fail Criteria
 
 **Pass:**

src/__tests__/authCors.test.ts

@@ -0,0 +1,60 @@
+import { describe, it, expect } from "vitest";
+import { enforceAuthCors } from "../lib/auth-cors.js";
+
+const TRUSTED = ["https://uat.groombook.dev", "https://dev.groombook.dev"];
+
+/** Simulates Better Auth reflecting the request Origin (the pre-fix bug). */
+function makeReflectedResponse(origin: string | null): Response {
+  return new Response('{"ok":true}', {
+    status: 200,
+    headers: {
+      "Content-Type": "application/json",
+      ...(origin
+        ? {
+            "Access-Control-Allow-Origin": origin,
+            "Access-Control-Allow-Credentials": "true",
+          }
+        : {}),
+    },
+  });
+}
+
+describe("enforceAuthCors (GRO-2586)", () => {
+  it("passes trusted origin through with credentials", () => {
+    const origin = "https://uat.groombook.dev";
+    const res = enforceAuthCors(origin, TRUSTED, makeReflectedResponse(origin));
+    expect(res.headers.get("Access-Control-Allow-Origin")).toBe(origin);
+    expect(res.headers.get("Access-Control-Allow-Credentials")).toBe("true");
+  });
+
+  it("strips ACAO for attacker origin (credentialed cross-origin read blocked)", () => {
+    const origin = "https://evil.example.com";
+    const res = enforceAuthCors(origin, TRUSTED, makeReflectedResponse(origin));
+    expect(res.headers.get("Access-Control-Allow-Origin")).toBeNull();
+    expect(res.headers.get("Access-Control-Allow-Credentials")).toBeNull();
+  });
+
+  it("strips ACAO when no Origin header (undefined)", () => {
+    const res = enforceAuthCors(undefined, TRUSTED, makeReflectedResponse(null));
+    expect(res.headers.get("Access-Control-Allow-Origin")).toBeNull();
+    expect(res.headers.get("Access-Control-Allow-Credentials")).toBeNull();
+  });
+
+  it("preserves non-CORS response headers and status from Better Auth", () => {
+    const origin = "https://evil.example.com";
+    const res = enforceAuthCors(origin, TRUSTED, makeReflectedResponse(origin));
+    expect(res.headers.get("Content-Type")).toBe("application/json");
+    expect(res.status).toBe(200);
+  });
+
+  it("second trusted origin is also allowed", () => {
+    const origin = "https://dev.groombook.dev";
+    const res = enforceAuthCors(origin, TRUSTED, makeReflectedResponse(origin));
+    expect(res.headers.get("Access-Control-Allow-Origin")).toBe(origin);
+  });
+
+  it("empty string origin is treated as untrusted", () => {
+    const res = enforceAuthCors("", TRUSTED, makeReflectedResponse(""));
+    expect(res.headers.get("Access-Control-Allow-Origin")).toBeNull();
+  });
+});

src/__tests__/portalClientsFromAuth.test.ts

@@ -0,0 +1,201 @@
+import { describe, it, expect, vi, beforeEach } from "vitest";
+import { Hono } from "hono";
+import { getAuth } from "../lib/auth.js";
+
+const NEW_USER_EMAIL = "new-sso-user@example.com";
+const NEW_USER_NAME = "New SSO User";
+const NEW_USER_ID = "11111111-2222-3333-4444-555555555555";
+
+const BETTER_AUTH_SESSION = {
+  user: {
+    id: "auth-user-new",
+    email: NEW_USER_EMAIL,
+    name: NEW_USER_NAME,
+  },
+  session: {
+    id: "ba-session-new",
+    expiresAt: new Date(Date.now() + 60 * 60 * 1000),
+  },
+};
+
+let mockGetAuth: ReturnType<typeof vi.fn>;
+let mockGetSession: ReturnType<typeof vi.fn>;
+let existingClientRow: Record<string, unknown> | null = null;
+let insertedClientValues: Record<string, unknown> | null = null;
+let insertShouldThrow: { code?: string } | null = null;
+
+function makeChainable(data: unknown[]): unknown {
+  const arr = [...data];
+  return new Proxy(arr, {
+    get(target, prop) {
+      if (prop === "where" || prop === "orderBy" || prop === "limit") {
+        return () => makeChainable(target);
+      }
+      // @ts-expect-error proxy
+      return target[prop];
+    },
+  });
+}
+
+vi.mock("@groombook/db", () => {
+  const clients = new Proxy(
+    { _name: "clients" },
+    { get: (t, p) => (p === "_name" ? "clients" : { table: "clients", column: p }) }
+  );
+
+  return {
+    getDb: () => ({
+      select: () => ({
+        from: (table: { _name: string }) => {
+          if (table._name === "clients") {
+            return makeChainable(existingClientRow ? [existingClientRow] : []);
+          }
+          return makeChainable([]);
+        },
+      }),
+      insert: (table: { _name: string }) => ({
+        values: (vals: Record<string, unknown>) => {
+          if (insertShouldThrow) {
+            const err = new Error("unique violation") as Error & { code?: string };
+            err.code = insertShouldThrow.code;
+            throw err;
+          }
+          return {
+            returning: () => {
+              if (table._name === "clients") {
+                insertedClientValues = { id: NEW_USER_ID, ...vals };
+                return [insertedClientValues];
+              }
+              return [];
+            },
+          };
+        },
+      }),
+    }),
+    clients,
+    eq: vi.fn(),
+    and: vi.fn(),
+    inArray: vi.fn(),
+  };
+});
+
+vi.mock("../lib/auth.js", () => ({
+  getAuth: vi.fn(),
+}));
+
+const { portalRouter } = await import("../routes/portal.js");
+
+const app = new Hono();
+app.route("/portal", portalRouter);
+
+describe("POST /portal/clients-from-auth (GRO-2359)", () => {
+  beforeEach(() => {
+    existingClientRow = null;
+    insertedClientValues = null;
+    insertShouldThrow = null;
+    mockGetSession = vi.fn();
+    mockGetAuth = vi.fn(() => ({
+      api: {
+        getSession: mockGetSession,
+      },
+    }));
+    vi.mocked(getAuth).mockImplementation(mockGetAuth);
+  });
+
+  it("returns 401 when no Better Auth session is present", async () => {
+    mockGetSession.mockResolvedValue(null);
+    const res = await app.request("/portal/clients-from-auth", {
+      method: "POST",
+      headers: { "Content-Type": "application/json" },
+      body: JSON.stringify({ name: "Test User" }),
+    });
+    expect(res.status).toBe(401);
+    const body = await res.json();
+    expect(body.error).toBe("Unauthorized");
+  });
+
+  it("returns 400 when body fails zod validation (empty name)", async () => {
+    mockGetSession.mockResolvedValue(BETTER_AUTH_SESSION);
+    const res = await app.request("/portal/clients-from-auth", {
+      method: "POST",
+      headers: { "Content-Type": "application/json" },
+      body: JSON.stringify({ name: "" }),
+    });
+    expect(res.status).toBe(400);
+  });
+
+  it("creates a new client row bound to the auth user's email and returns 201", async () => {
+    mockGetSession.mockResolvedValue(BETTER_AUTH_SESSION);
+    const res = await app.request("/portal/clients-from-auth", {
+      method: "POST",
+      headers: { "Content-Type": "application/json" },
+      body: JSON.stringify({
+        name: " New SSO User ",
+        phone: "555-1234",
+        address: "1 Main St",
+        notes: "test note",
+      }),
+    });
+    expect(res.status).toBe(201);
+    const body = await res.json();
+    expect(body).toMatchObject({
+      id: NEW_USER_ID,
+      name: "New SSO User",
+      email: NEW_USER_EMAIL,
+    });
+    // Trim must be applied to the persisted values.
+    expect(insertedClientValues).not.toBeNull();
+    expect((insertedClientValues as Record<string, unknown>).name).toBe("New SSO User");
+    expect((insertedClientValues as Record<string, unknown>).email).toBe(NEW_USER_EMAIL);
+    expect((insertedClientValues as Record<string, unknown>).phone).toBe("555-1234");
+  });
+
+  it("normalizes empty optional fields to null on insert", async () => {
+    mockGetSession.mockResolvedValue(BETTER_AUTH_SESSION);
+    await app.request("/portal/clients-from-auth", {
+      method: "POST",
+      headers: { "Content-Type": "application/json" },
+      body: JSON.stringify({ name: "Test", phone: "", address: "   " }),
+    });
+    expect(insertedClientValues).not.toBeNull();
+    expect((insertedClientValues as Record<string, unknown>).phone).toBeNull();
+    expect((insertedClientValues as Record<string, unknown>).address).toBeNull();
+  });
+
+  it("returns 409 when a client row already exists for this email", async () => {
+    mockGetSession.mockResolvedValue(BETTER_AUTH_SESSION);
+    existingClientRow = { id: "existing-client-id", email: NEW_USER_EMAIL };
+    const res = await app.request("/portal/clients-from-auth", {
+      method: "POST",
+      headers: { "Content-Type": "application/json" },
+      body: JSON.stringify({ name: "Test" }),
+    });
+    expect(res.status).toBe(409);
+    const body = await res.json();
+    expect(body.error).toMatch(/already exists/i);
+    expect(insertedClientValues).toBeNull();
+  });
+
+  it("returns 409 on unique constraint race (23505)", async () => {
+    mockGetSession.mockResolvedValue(BETTER_AUTH_SESSION);
+    insertShouldThrow = { code: "23505" };
+    const res = await app.request("/portal/clients-from-auth", {
+      method: "POST",
+      headers: { "Content-Type": "application/json" },
+      body: JSON.stringify({ name: "Test" }),
+    });
+    expect(res.status).toBe(409);
+  });
+
+  it("returns 503 when auth is not configured", async () => {
+    mockGetAuth.mockImplementation(() => {
+      throw new Error("Auth not initialized");
+    });
+    const res = await app.request("/portal/clients-from-auth", {
+      method: "POST",
+      headers: { "Content-Type": "application/json" },
+      body: JSON.stringify({ name: "Test" }),
+    });
+    expect(res.status).toBe(503);
+  });
+});

src/index.ts

@@ -3,6 +3,7 @@ import { Hono } from "hono";
 import { logger } from "hono/logger";
 import { cors } from "hono/cors";
 import { getAuth, initAuth, getActiveProviders } from "./lib/auth.js";
+import { enforceAuthCors } from "./lib/auth-cors.js";
 import { clientsRouter } from "./routes/clients.js";
 import { petsRouter } from "./routes/pets.js";
 import { servicesRouter } from "./routes/services.js";
@@ -200,9 +201,10 @@ api.use("*", resolveStaffMiddleware);
 // Better-Auth handler — mounted as sub-app to handle all /api/auth/* routes
 // authMiddleware and resolveStaffMiddleware both skip /api/auth/ paths
 const authRouter = new Hono();
-authRouter.all("/*", (c) => {
+authRouter.all("/*", async (c) => {
   try {
-    return getAuth().handler(c.req.raw);
+    const res = await getAuth().handler(c.req.raw);
+    return enforceAuthCors(c.req.header("origin"), TRUSTED_ORIGINS, res);
   } catch {
     return c.json({ error: "Authentication not configured" }, 503);
   }
@@ -290,14 +292,34 @@ api.route("/search", searchRouter);
 api.route("/buffer-rules", bufferRulesRouter);
 api.route("/routes", routesRouter);
 
+// Start the HTTP server first so /health and public routes are available immediately.
+// Auth initialization runs afterward with retry — a transient DB ECONNRESET at boot
+// must not crash the process (GRO-2652). Auth routes return 503 until initAuth succeeds.
 const port = Number(process.env.PORT ?? 3000);
-await initAuth();
-console.log(`API server listening on port ${port}`);
 const server = serve({ fetch: app.fetch, port });
+console.log(`API server listening on port ${port}`);
 
 // Start background reminder scheduler (runs every minute to check for upcoming appointments)
 startReminderScheduler();
 
+let initAttempt = 0;
+while (true) {
+  try {
+    await initAuth();
+    break;
+  } catch (err) {
+    initAttempt++;
+    const delay = Math.min(2 ** initAttempt * 500, 30_000);
+    console.error(`[auth] initAuth attempt ${initAttempt} failed: ${err}`);
+    if (initAttempt >= 10) {
+      console.error("[auth] auth init permanently failed — auth endpoints will serve 503");
+      break;
+    }
+    console.error(`[auth] retrying in ${delay}ms`);
+    await new Promise((r) => setTimeout(r, delay));
+  }
+}
+
 function shutdown() {
   console.log("Shutting down gracefully...");
   // SIGTERM/SIGINT → server.close() → callback → process.exit(0)

src/lib/auth-cors.ts

@@ -0,0 +1,22 @@
+/**
+ * Enforces the trusted-origins CORS allowlist on a raw Response from Better Auth.
+ * Better Auth reflects the request Origin into Access-Control-Allow-Origin
+ * regardless of the trustedOrigins config, allowing credentialed cross-origin reads
+ * from arbitrary attacker origins. This wrapper strips CORS headers for any origin
+ * not in the allowlist. (GRO-2586)
+ */
+export function enforceAuthCors(
+  requestOrigin: string | undefined,
+  trustedOrigins: string[],
+  res: Response
+): Response {
+  const headers = new Headers(res.headers);
+  if (requestOrigin && trustedOrigins.includes(requestOrigin)) {
+    headers.set("Access-Control-Allow-Origin", requestOrigin);
+    headers.set("Access-Control-Allow-Credentials", "true");
+  } else {
+    headers.delete("Access-Control-Allow-Origin");
+    headers.delete("Access-Control-Allow-Credentials");
+  }
+  return new Response(res.body, { status: res.status, statusText: res.statusText, headers });
+}

src/lib/auth.ts

@@ -118,18 +118,34 @@ export async function initAuth(): Promise<void> {
           updateAge: 60 * 60 * 24,
           cookieCache: { enabled: false },
         },
-        trustedOrigins: [process.env.CORS_ORIGIN ?? "http://localhost:5173"],
+        trustedOrigins: (process.env.CORS_ORIGIN ?? "http://localhost:5173")
+          .split(",").map((s) => s.trim()).filter(Boolean),
       });
       return;
     }
 
-    // Step 1: Try to load config from DB
+    // Step 1: Try to load config from DB, with retry-with-backoff for transient ECONNRESET (GRO-2652).
+    // A single connection reset during boot must not abort initialization.
     const db = getDb();
-    const [dbConfig] = await db
-      .select()
-      .from(authProviderConfig)
-      .where(eq(authProviderConfig.enabled, true))
-      .limit(1);
+    let dbQueryRows: (typeof authProviderConfig.$inferSelect)[] = [];
+    let dbAttempt = 0;
+    while (true) {
+      try {
+        dbQueryRows = await db
+          .select()
+          .from(authProviderConfig)
+          .where(eq(authProviderConfig.enabled, true))
+          .limit(1);
+        break;
+      } catch (err) {
+        dbAttempt++;
+        if (dbAttempt >= 5) throw err;
+        const delay = Math.min(1000 * 2 ** (dbAttempt - 1), 8_000);
+        console.warn(`[auth] DB query attempt ${dbAttempt} failed (${err}), retrying in ${delay}ms`);
+        await new Promise((r) => setTimeout(r, delay));
+      }
+    }
+    const [dbConfig] = dbQueryRows;
 
     let providerConfig: {
       providerId: string;
@@ -308,7 +324,8 @@ export async function initAuth(): Promise<void> {
           maxAge: 5 * 60, // 5 minutes
         },
       },
-      trustedOrigins: [process.env.CORS_ORIGIN ?? "http://localhost:5173"],
+      trustedOrigins: (process.env.CORS_ORIGIN ?? "http://localhost:5173")
+        .split(",").map((s) => s.trim()).filter(Boolean),
     });
   })();
 

src/routes/portal.ts

@@ -147,6 +147,114 @@ portalRouter.post("/session-from-auth", async (c) => {
   );
 });
 
+// GRO-2359 — register a brand-new SSO user. The post-auth handler in the
+// web portal redirects here when `session-from-auth` returns 404, so the
+// OOBE can complete a customer record for the new user. Auth is via the
+// Better Auth session (same shape as `session-from-auth`), so this is
+// registered BEFORE the `validatePortalSession` middleware.
+//
+// Contract:
+//   POST /api/portal/clients-from-auth
+//   Body: { name: string; phone?: string|null; address?: string|null; notes?: string|null }
+//   201:  { id, name, email }
+//   400:  invalid body (zod failure)
+//   401:  no Better Auth session
+//   409:  a `clients` row already exists for this email (portal selection case)
+//   500:  insert failed
+//
+// We do NOT auto-link the user's auth account to the new client row; the
+// existing `session-from-auth` endpoint re-resolves the row by email on the
+// next call, so the OOBE's success path just navigates the user back to
+// `/` and lets the bridge mint a portal session.
+const createClientFromAuthSchema = z.object({
+  name: z.string().min(1).max(200),
+  phone: z.string().max(50).nullish(),
+  address: z.string().max(500).nullish(),
+  notes: z.string().max(2000).nullish(),
+});
+
+portalRouter.post(
+  "/clients-from-auth",
+  zValidator("json", createClientFromAuthSchema),
+  async (c) => {
+    let auth;
+    try {
+      auth = getAuth();
+    } catch {
+      return c.json({ error: "Authentication not configured" }, 503);
+    }
+
+    const session = await auth.api.getSession({
+      headers: c.req.raw.headers,
+    });
+
+    if (!session) {
+      return c.json({ error: "Unauthorized" }, 401);
+    }
+
+    const body = c.req.valid("json");
+    const db = getDb();
+
+    // Pre-check: if a client already exists for this email, return 409 so
+    // the OOBE can render the "portal selection" message (the user needs
+    // to contact their groomer to link the new SSO identity to the
+    // pre-existing customer record). We don't return the existing row to
+    // avoid leaking PII about other accounts.
+    const [existing] = await db
+      .select({ id: clients.id })
+      .from(clients)
+      .where(eq(clients.email, session.user.email))
+      .limit(1);
+
+    if (existing) {
+      return c.json(
+        { error: "A customer record with this email already exists" },
+        409,
+      );
+    }
+
+    let row;
+    try {
+      [row] = await db
+        .insert(clients)
+        .values({
+          name: body.name.trim(),
+          email: session.user.email,
+          phone: body.phone?.trim() || null,
+          address: body.address?.trim() || null,
+          notes: body.notes?.trim() || null,
+        })
+        .returning();
+    } catch (err) {
+      // Concurrent insert from a parallel OOBE submit — treat as 409.
+      if (
+        err instanceof Error &&
+        "code" in err &&
+        (err as { code?: string }).code === "23505"
+      ) {
+        return c.json(
+          { error: "A customer record with this email already exists" },
+          409,
+        );
+      }
+      throw err;
+    }
+
+    if (!row) {
+      return c.json({ error: "Failed to create client" }, 500);
+    }
+
+    return c.json(
+      {
+        id: row.id,
+        name: row.name,
+        email: row.email,
+      },
+      201,
+    );
+  },
+);
+
 // Apply middleware to all portal routes
 portalRouter.use("/*", validatePortalSession, portalAudit);