fix(test): delayed process.exit(0) in 8 test files silently truncates full bun-test runs

browse/src/browser-manager.ts

@@ -803,15 +803,14 @@ export class BrowserManager {
     this.tabSessions.delete(tabId);
     this.tabOwnership.delete(tabId);
 
-    // Switch to another tab if we closed the active one
-    if (tabId === this.activeTabId) {
+    // Never leave zero tabs, regardless of which tab was closed — activeTabId
+    // can point at an already-removed id, and the old active-only guard then
+    // skipped auto-create when the last tab closed.
+    if (this.pages.size === 0) {
+      await this.newTab();
+    } else if (tabId === this.activeTabId) {
       const remaining = [...this.pages.keys()];
-      if (remaining.length > 0) {
-        this.activeTabId = remaining[remaining.length - 1];
-      } else {
-        // No tabs left — create a new blank one
-        await this.newTab();
-      }
+      this.activeTabId = remaining[remaining.length - 1];
     }
   }
 

browse/src/server.ts

@@ -243,6 +243,14 @@ export interface ServerConfig {
    * reference is the PID record + the file paths.
    */
   ownsTerminalAgent?: boolean;
+  /**
+   * Process-exit seam. shutdown() calls this at the very end of its async
+   * teardown; defaults to process.exit. In-process test runs inject a
+   * recording stub here — the fire-and-forget shutdown path otherwise races
+   * per-test process.exit stubs, and a straggler real exit(0) truncates the
+   * whole bun test run with a green exit code and no failure tally.
+   */
+  exitFn?: (code?: number) => void;
 }
 
 /**
@@ -664,6 +672,11 @@ export const __testInternals__ = {
   // need shutdown to fire. Without this, the second test's shutdown
   // returns early at the `if (isShuttingDown) return;` guard.
   resetShutdownState: () => { isShuttingDown = false; },
+  // Stop the module-level 60s idle interval. In-process test runs import this
+  // module once for the whole suite; the interval otherwise outlives the test
+  // file and can fire a real process.exit(0) mid-suite, silently truncating
+  // the run with a green exit code.
+  stopIdleTimer: () => { clearInterval(idleCheckInterval); },
 };
 
 // ─── Parent-Process Watchdog ────────────────────────────────────────
@@ -1489,6 +1502,9 @@ export function buildFetchHandler(cfg: ServerConfig): ServerHandle {
   // to gstack-owns. Matches the "default-true preserves CLI bit-for-bit"
   // premise even under malformed cfg.
   const ownsTerminalAgent = cfg.ownsTerminalAgent === false ? false : true;
+  // Exit seam: production defaults to process.exit; tests inject a stub so
+  // in-process shutdowns can never terminate the test runner itself.
+  const exitFn = cfg.exitFn ?? ((code?: number) => process.exit(code));
 
   // ─── Terminal-Agent Watchdog (v1.44+) ─────────────────────────────
   //
@@ -1614,7 +1630,7 @@ export function buildFetchHandler(cfg: ServerConfig): ServerHandle {
 
     cleanSingletonLocks(resolveChromiumProfile());
     safeUnlinkQuiet(config.stateFile);
-    process.exit(exitCode);
+    exitFn(exitCode);
   }
 
   // Named lifecycle helper (matches closeTunnel style). Logs failures so

browse/test/batch.test.ts

@@ -42,9 +42,16 @@ beforeAll(async () => {
   // The test needs to start a server. Let's use the existing server infrastructure.
 });
 
-afterAll(() => {
+afterAll(async () => {
   try { testServer.server.stop(); } catch {}
-  setTimeout(() => process.exit(0), 500);
+  // Close the real browser (capped at 5s — close can hang) instead of a
+  // delayed process.exit(0): that timer fired ~500ms into the NEXT test
+  // file in a full-suite run and killed the whole bun process with a green
+  // exit code and no tally, silently truncating the run.
+  await Promise.race([
+    bm.close().catch(() => {}),
+    new Promise<void>(r => setTimeout(r, 5000)),
+  ]);
 });
 
 // We need a running browse server for HTTP tests.

browse/test/cdp-e2e.test.ts

@@ -18,6 +18,7 @@ import { startTestServer } from './test-server';
 import { BrowserManager } from '../src/browser-manager';
 
 const TMP_HOME = path.join(os.tmpdir(), `gstack-cdp-e2e-${process.pid}-${Date.now()}`);
+const ORIG_GSTACK_HOME = process.env.GSTACK_HOME;
 process.env.GSTACK_HOME = TMP_HOME;
 process.env.GSTACK_TELEMETRY_OFF = '1'; // don't pollute analytics during tests
 
@@ -36,6 +37,11 @@ beforeAll(async () => {
 });
 
 afterAll(async () => {
+  // Un-leak GSTACK_HOME: it outranks GSTACK_STATE_DIR in bin/gstack-config,
+  // so leaving it set breaks later test files in-process.
+  if (ORIG_GSTACK_HOME === undefined) delete process.env.GSTACK_HOME;
+  else process.env.GSTACK_HOME = ORIG_GSTACK_HOME;
+
   try { await bm.cleanup?.(); } catch {}
   try { testServer.server.stop(); } catch {}
   await fs.rm(TMP_HOME, { recursive: true, force: true });

browse/test/commands.test.ts

@@ -94,11 +94,18 @@ beforeAll(async () => {
   await bm.launch();
 });
 
-afterAll(() => {
+afterAll(async () => {
   // Force kill browser instead of graceful close (avoids hang)
   try { testServer.server.stop(); } catch {}
   // bm.close() can hang — just let process exit handle it
-  setTimeout(() => process.exit(0), 500);
+  // Close the real browser (capped at 5s — close can hang) instead of a
+  // delayed process.exit(0): that timer fired ~500ms into the NEXT test
+  // file in a full-suite run and killed the whole bun process with a green
+  // exit code and no tally, silently truncating the run.
+  await Promise.race([
+    bm.close().catch(() => {}),
+    new Promise<void>(r => setTimeout(r, 5000)),
+  ]);
 });
 
 // ─── Navigation ─────────────────────────────────────────────────

browse/test/compare-board.test.ts

@@ -69,10 +69,17 @@ beforeAll(async () => {
   await handleWriteCommand('goto', [boardUrl], bm);
 });
 
-afterAll(() => {
+afterAll(async () => {
   try { server.stop(); } catch {}
   fs.rmSync(tmpDir, { recursive: true, force: true });
-  setTimeout(() => process.exit(0), 500);
+  // Close the real browser (capped at 5s — close can hang) instead of a
+  // delayed process.exit(0): that timer fired ~500ms into the NEXT test
+  // file in a full-suite run and killed the whole bun process with a green
+  // exit code and no tally, silently truncating the run.
+  await Promise.race([
+    bm.close().catch(() => {}),
+    new Promise<void>(r => setTimeout(r, 5000)),
+  ]);
 });
 
 // ─── DOM Structure ──────────────────────────────────────────────

browse/test/content-security.test.ts

@@ -422,9 +422,16 @@ describe('Hidden element stripping', () => {
     await bm.launch();
   });
 
-  afterAll(() => {
+  afterAll(async () => {
     try { testServer.server.stop(); } catch {}
-    setTimeout(() => process.exit(0), 500);
+    // Close the real browser (capped at 5s — close can hang) instead of a
+    // delayed process.exit(0): that timer fired ~500ms into the NEXT test
+    // file in a full-suite run and killed the whole bun process with a green
+    // exit code and no tally, silently truncating the run.
+    await Promise.race([
+      bm.close().catch(() => {}),
+      new Promise<void>(r => setTimeout(r, 5000)),
+    ]);
   });
 
   test('detects CSS-hidden elements on injection-hidden page', async () => {

browse/test/domain-skills-e2e.test.ts

@@ -17,6 +17,7 @@ import { startTestServer } from './test-server';
 import { BrowserManager } from '../src/browser-manager';
 
 const TMP_HOME = path.join(os.tmpdir(), `gstack-domain-e2e-${process.pid}-${Date.now()}`);
+const ORIG_GSTACK_HOME = process.env.GSTACK_HOME;
 process.env.GSTACK_HOME = TMP_HOME;
 process.env.GSTACK_PROJECT_SLUG = 'e2e-test-slug';
 
@@ -41,6 +42,11 @@ beforeAll(async () => {
 });
 
 afterAll(async () => {
+  // Un-leak GSTACK_HOME: it outranks GSTACK_STATE_DIR in bin/gstack-config,
+  // so leaving it set breaks later test files in-process.
+  if (ORIG_GSTACK_HOME === undefined) delete process.env.GSTACK_HOME;
+  else process.env.GSTACK_HOME = ORIG_GSTACK_HOME;
+
   try { await bm.cleanup?.(); } catch {}
   try { testServer.server.stop(); } catch {}
   await fs.rm(TMP_HOME, { recursive: true, force: true });

browse/test/domain-skills-storage.test.ts

@@ -1,11 +1,19 @@
-import { describe, it, expect, beforeEach } from 'bun:test';
+import { describe, it, expect, beforeEach, afterAll } from 'bun:test';
 import { promises as fs } from 'fs';
 import * as path from 'path';
 import * as os from 'os';
 
 const TMP_HOME = path.join(os.tmpdir(), `gstack-test-${process.pid}-${Date.now()}`);
+const ORIG_GSTACK_HOME = process.env.GSTACK_HOME;
 process.env.GSTACK_HOME = TMP_HOME;
 
+afterAll(() => {
+  // Un-leak GSTACK_HOME: it outranks GSTACK_STATE_DIR in bin/gstack-config,
+  // so leaving it set breaks later test files in-process.
+  if (ORIG_GSTACK_HOME === undefined) delete process.env.GSTACK_HOME;
+  else process.env.GSTACK_HOME = ORIG_GSTACK_HOME;
+});
+
 // Re-import after env var set so module reads updated GSTACK_HOME
 async function freshImport() {
   // Bun caches modules; force reload by appending a query-string-like hack via dynamic import URL

browse/test/gstack-config.test.ts

@@ -18,7 +18,12 @@ function run(args: string[] = [], extraEnv: Record<string, string> = {}) {
   const result = Bun.spawnSync(['bash', SCRIPT, ...args], {
     env: {
       ...process.env,
+      // Set all three state-dir vars: other test files leak GSTACK_HOME /
+      // GSTACK_STATE_ROOT into process.env at module scope, and those
+      // outrank GSTACK_STATE_DIR in the script's resolution order.
       GSTACK_STATE_DIR: stateDir,
+      GSTACK_STATE_ROOT: stateDir,
+      GSTACK_HOME: stateDir,
       ...extraEnv,
     },
     stdout: 'pipe',

browse/test/handoff.test.ts

@@ -26,9 +26,16 @@ beforeAll(async () => {
   await bm.launch();
 });
 
-afterAll(() => {
+afterAll(async () => {
   try { testServer.server.stop(); } catch {}
-  setTimeout(() => process.exit(0), 500);
+  // Close the real browser (capped at 5s — close can hang) instead of a
+  // delayed process.exit(0): that timer fired ~500ms into the NEXT test
+  // file in a full-suite run and killed the whole bun process with a green
+  // exit code and no tally, silently truncating the run.
+  await Promise.race([
+    bm.close().catch(() => {}),
+    new Promise<void>(r => setTimeout(r, 5000)),
+  ]);
 });
 
 // ─── Unit Tests: Failure Tracking (no browser needed) ────────────

browse/test/security-live-playwright.test.ts

@@ -56,9 +56,16 @@ describe('defense-in-depth — live Playwright fixture', () => {
     await bm.launch();
   });
 
-  afterAll(() => {
+  afterAll(async () => {
     try { testServer.server.stop(); } catch {}
-    setTimeout(() => process.exit(0), 500);
+    // Close the real browser (capped at 5s — close can hang) instead of a
+    // delayed process.exit(0): that timer fired ~500ms into the NEXT test
+    // file in a full-suite run and killed the whole bun process with a green
+    // exit code and no tally, silently truncating the run.
+    await Promise.race([
+      bm.close().catch(() => {}),
+      new Promise<void>(r => setTimeout(r, 5000)),
+    ]);
   });
 
   test('L2 — content-security.ts hidden-element stripper detects the .sneaky div', async () => {