From 7d5544493e80936d0d661f5b90e2ec49f0ccfe93 Mon Sep 17 00:00:00 2001
From: roboomp <omp@can.ac>
Date: Mon, 29 Jun 2026 11:06:17 +0000
Subject: [PATCH] fix(stats): skipped sync worker smoke on darwin

smokeTestSyncWorker spawned a worker via createSyncWorker on every platform, so omp --smoke-test (and the macOS signing pre-launch run in scripts/ci-macos-sign.sh) still hit the Bun-worker re-entry path the serial macOS sync default avoids. Early-return on darwin and document the carve-out.

Fixes #3733
---
 packages/stats/CHANGELOG.md                   |  1 +
 packages/stats/src/aggregator.ts              | 10 +++++++--
 .../stats/test/smoke-worker-darwin.test.ts    | 21 +++++++++++++++++++
 3 files changed, 30 insertions(+), 2 deletions(-)
 create mode 100644 packages/stats/test/smoke-worker-darwin.test.ts

diff --git a/packages/stats/CHANGELOG.md b/packages/stats/CHANGELOG.md
index 5e2a32afd..de604061f 100644
--- a/packages/stats/CHANGELOG.md
+++ b/packages/stats/CHANGELOG.md
@@ -6,6 +6,7 @@
 
 - Kept stats session sync on the serial parser path for `workers: 1` and macOS defaults, avoiding Bun worker re-entry aborts when launching `/stats` ([#3733](https://github.com/can1357/oh-my-pi/issues/3733)).
 - Replaced the native `Bun.JSONL.parseChunk` session parser path with a lenient JS line scanner, avoiding Bun aborts on large stats session files ([#3733](https://github.com/can1357/oh-my-pi/issues/3733)).
+- Skipped the stats sync worker smoke probe on darwin so `omp --smoke-test` (and the macOS signing/notarization pre-launch run) no longer re-enters the Bun-worker abort surface the serial macOS sync now avoids ([#3733](https://github.com/can1357/oh-my-pi/issues/3733)).
 
 ## [16.2.3] - 2026-06-28
 
diff --git a/packages/stats/src/aggregator.ts b/packages/stats/src/aggregator.ts
index 3f3c5439d..1aec92565 100644
--- a/packages/stats/src/aggregator.ts
+++ b/packages/stats/src/aggregator.ts
@@ -152,10 +152,16 @@ function dispatch(handle: WorkerHandle, request: SyncWorkerRequest): Promise<Par
  * spawn path on a fresh install (no session files = early return), so a
  * dedicated probe is the only reliable signal.
  *
- * Resolves with the worker's `import.meta.url` (caller-visible diagnostics);
- * rejects on transport error, error response, or timeout.
+ * No-op on darwin: `syncAllSessions` keeps macOS on the serial parser path
+ * (see {@link defaultWorkerCount}) so the worker spawn surface is unreachable
+ * from the CLI, and probing it under the hardened runtime in
+ * `scripts/ci-macos-sign.sh` would re-enter the Bun-worker abort surface that
+ * motivated the darwin serial default in the first place.
+ *
+ * Rejects on transport error, error response, or timeout.
  */
 export async function smokeTestSyncWorker({ timeoutMs = 5_000 }: { timeoutMs?: number } = {}): Promise<void> {
+	if (process.platform === "darwin") return;
 	const worker = createSyncWorker();
 	const { promise, resolve, reject } = Promise.withResolvers<void>();
 	const timer = setTimeout(() => reject(new Error(`sync worker did not pong within ${timeoutMs}ms`)), timeoutMs);
diff --git a/packages/stats/test/smoke-worker-darwin.test.ts b/packages/stats/test/smoke-worker-darwin.test.ts
new file mode 100644
index 000000000..b1a23d0f8
--- /dev/null
+++ b/packages/stats/test/smoke-worker-darwin.test.ts
@@ -0,0 +1,21 @@
+import { afterEach, describe, expect, it, vi } from "bun:test";
+import { smokeTestSyncWorker } from "@oh-my-pi/omp-stats/aggregator";
+import { installStatsTestIsolation } from "./helpers/temp-agent";
+
+installStatsTestIsolation("@pi-stats-smoke-darwin-");
+
+afterEach(() => {
+	vi.restoreAllMocks();
+});
+
+describe("smokeTestSyncWorker", () => {
+	it("skips the worker spawn on darwin so omp --smoke-test stays off the macOS abort surface", async () => {
+		vi.spyOn(process, "platform", "get").mockReturnValue("darwin");
+		const workerSpy = vi.spyOn(globalThis, "Worker").mockImplementation(() => {
+			throw new Error("worker should not be created on darwin");
+		});
+
+		await expect(smokeTestSyncWorker()).resolves.toBeUndefined();
+		expect(workerSpy).not.toHaveBeenCalled();
+	});
+});