fix(update): bundle app-update.yml so electron-updater can install (forge omits it) (#2244)

* fix(update): generate app-update.yml at build time; drop runtime setFeedURL

electron-forge does not emit app-update.yml; electron-updater requires it at
process.resourcesPath to resolve the GitHub release feed. Without it every
packaged app threw ENOENT on the first download attempt, making updates
detected but never installed.

Two-part fix:
- forge.config.ts: add postPackage hook that writes app-update.yml into
  each platform's Resources dir (baked from AO_RELEASE_REPO so fork builds
  point at the fork, prod at AgentWrapper/agent-orchestrator).
- auto-updater.ts: remove setFeedURL + repo() + DEFAULT_RELEASE_REPO;
  configureFeed now only sets channel + allowDowngrade. electron-updater
  auto-loads the bundled yml on the first checkForUpdates call.

Co-Authored-By: Claude Opus 4.8 <noreply@anthropic.com>

* chore: format with prettier [skip ci]

* fix(update): generate app-update.yml before signing, not after

The postPackage hook wrote app-update.yml into Contents/Resources AFTER osxSign
sealed the bundle, so the added file was unsealed and macOS reported the app as
"damaged" (codesign: "a sealed resource is missing or invalid"). Generate it in
a prePackage hook and ship it via packagerConfig.extraResource, so it is copied
into the bundle and signed as part of the seal. The generated app-update.yml is
gitignored.

Co-Authored-By: Claude Opus 4.8 <noreply@anthropic.com>

* chore: format with prettier [skip ci]

* ci(release): move Intel leg to macos-15-intel and gate the feed on it

macos-13 is deprecated and has no runner capacity (multi-hour queues),
so the detached release-intel leg never completed. Switch it to the
supported macos-15-intel image in both the release and nightly workflows.

Now that the Intel leg gets a runner and builds + signs the x64 installer
reliably (verified on fork v0.10.10), re-couple it into publish-feed
(needs: [release, release-intel]) so latest-mac.yml / nightly-mac.yml
always carry the x64 entry and Intel macOS users receive auto-updates.

Co-Authored-By: Claude Opus 4.8 <noreply@anthropic.com>

---------

Co-authored-by: Claude Opus 4.8 <noreply@anthropic.com>
Co-authored-by: github-actions[bot] <github-actions[bot]@users.noreply.github.com>

.github/workflows/frontend-nightly.yml

@@ -93,15 +93,15 @@ jobs:
           # macOS signing + notarization env is exported by the "macOS signing
           # setup" step above via $GITHUB_ENV; the cert is in the keychain.
 
-  # Dedicated Intel (darwin-x64) nightly build leg, decoupled from the release
-  # matrix so the scarce macos-13 runner does not block publish-feed. Mirrors
-  # the release job's macOS steps exactly. publish-feed stays needs: release
-  # only (three fast legs); the x64 feed entry appears if this job finishes
-  # first, but the feed is not gated on it.
+  # Dedicated Intel (darwin-x64) nightly build leg. Kept separate from the
+  # release matrix (only a macOS host can build the x64 installer); publish-feed
+  # now waits on it so the x64 entry is present in nightly-mac.yml and Intel
+  # nightly users get auto-updates. Mirrors the release job's macOS steps exactly.
+  # Runner is macos-15-intel (macos-13 deprecated/no capacity; see release wf).
   release-intel:
     needs: guard
     if: needs.guard.outputs.should_build == 'true'
-    runs-on: macos-13
+    runs-on: macos-15-intel
     permissions:
       contents: write
     defaults:
@@ -161,7 +161,7 @@ jobs:
   # assets. The nightly version is only stamped in-memory on the build runners,
   # so derive the tag from the guard job's computed version, not package.json.
   publish-feed:
-    needs: [guard, release]
+    needs: [guard, release, release-intel]
     runs-on: ubuntu-latest
     permissions:
       contents: write

.github/workflows/frontend-release.yml

@@ -92,7 +92,7 @@ jobs:
       # release the publish step just created, with --clobber (so re-runs replace).
       #
       # Arch-coverage note: each runner only builds its host arch. macos-latest
-      # (Apple silicon) produces darwin-arm64; macos-13 (Intel x64) produces
+      # (Apple silicon) produces darwin-arm64; macos-15-intel (Intel x64) produces
       # darwin-x64. Both macOS runners run this step (see the `if` below), so the
       # arm64 and x64 stable aliases are now both built (spec §8).
       # The Linux stable name is undecided (spec §11.3), so we build the deb/rpm
@@ -155,13 +155,14 @@ jobs:
         env:
           GH_TOKEN: ${{ secrets.GITHUB_TOKEN }}
 
-  # Dedicated Intel (darwin-x64) build leg, decoupled from the release matrix so
-  # the scarce macos-13 runner does not block publish-feed. publish-feed needs
-  # only the three fast legs (release); this job uploads the x64 installer and
-  # stable alias independently. feed.mjs includes the x64 entry if this job
-  # finishes before publish-feed, but the feed is not gated on it.
+  # Dedicated Intel (darwin-x64) build leg. Kept a separate job (not in the
+  # release matrix) because only a macOS host can build the x64 installer, but
+  # publish-feed now waits on it (needs: [release, release-intel]) so the x64
+  # entry is always present in latest-mac.yml and Intel users get auto-updates.
+  # Runner is macos-15-intel: macos-13 is deprecated/has no capacity (multi-hour
+  # queues), so this leg uses the supported Intel x64 image.
   release-intel:
-    runs-on: macos-13
+    runs-on: macos-15-intel
     environment: release # same approval gate as the matrix release job
     permissions:
       contents: write
@@ -216,7 +217,7 @@ jobs:
   # assets and upload them to the same release. Runs once, on Linux: it only
   # hashes already-built artifacts, so it needs no per-OS runner.
   publish-feed:
-    needs: release
+    needs: [release, release-intel]
     runs-on: ubuntu-latest
     permissions:
       contents: write

frontend/.gitignore

@@ -0,0 +1 @@
+app-update.yml

frontend/forge.config.ts

@@ -2,6 +2,7 @@ import type { ForgeConfig } from "@electron-forge/shared-types";
 import { VitePlugin } from "@electron-forge/plugin-vite";
 import MakerNSIS from "./makers/maker-nsis";
 import MakerAppImage from "./makers/maker-appimage";
+import { writeFileSync } from "node:fs";
 
 // Default GitHub release target (production). aoagents was the temporary rewrite
 // home; releases land on AgentWrapper (spec §1.1).
@@ -30,7 +31,7 @@ const config: ForgeConfig = {
 		// (.icns on macOS, .ico on Windows); Linux menu icons come from the
 		// deb/rpm makers below, and the runtime window icon from src/main.ts.
 		icon: "assets/icon",
-		extraResource: ["daemon", "assets/icon.png"],
+		extraResource: ["daemon", "assets/icon.png", "app-update.yml"],
 		// Notarization. Two paths:
 		//  - CI: an App Store Connect API key. APPLE_API_KEY is a PATH to the .p8
 		//    (the workflow decodes APPLE_API_KEY_BASE64 to a temp file), plus the
@@ -53,6 +54,27 @@ const config: ForgeConfig = {
 					}
 				: undefined,
 	},
+	hooks: {
+		// electron-forge does not generate app-update.yml (electron-builder does);
+		// electron-updater reads it from the app's Resources dir at runtime to know
+		// which GitHub repo to pull from, else it throws ENOENT during download.
+		// Generate it in prePackage (BEFORE osxSign) and ship it via extraResource
+		// above, so it is copied into the bundle and SIGNED as part of the seal.
+		// Writing it after signing (a postPackage hook) adds an unsealed resource
+		// and macOS reports the app as "damaged". owner/repo are baked from
+		// AO_RELEASE_REPO at build time.
+		prePackage: async () => {
+			const { owner, name } = parseReleaseRepo(process.env.AO_RELEASE_REPO);
+			const yml = [
+				"provider: github",
+				`owner: ${owner}`,
+				`repo: ${name}`,
+				"updaterCacheDirName: agent-orchestrator-updater",
+				"",
+			].join("\n");
+			writeFileSync("app-update.yml", yml);
+		},
+	},
 	rebuildConfig: {},
 	makers: [
 		// Windows installer: NSIS via electron-builder (see makers/maker-nsis.ts).

frontend/src/main/auto-updater.ts

@@ -10,22 +10,12 @@ import {
 	type UpdateStatus,
 } from "./update-settings";
 
-// Default release repo, mirroring backend cli.releaseRepo. Override via env for
-// fork test builds (AO_RELEASE_REPO=owner/repo).
-const DEFAULT_RELEASE_REPO = "AgentWrapper/agent-orchestrator";
-
-function repo(): { owner: string; name: string } {
-	const [owner, name] = (process.env.AO_RELEASE_REPO || DEFAULT_RELEASE_REPO).split("/");
-	if (owner && name) return { owner, name };
-	const [defOwner, defName] = DEFAULT_RELEASE_REPO.split("/");
-	return { owner: defOwner, name: defName };
-}
-
-// configureFeed points electron-updater at the GitHub Releases feed for the
-// chosen channel. Shared by the launch auto-check and the manual Settings flow.
+// configureFeed sets the update channel on electron-updater. The repo/owner
+// are loaded automatically from app-update.yml (written by forge.config.ts's
+// postPackage hook into the app's Resources dir at build time). No runtime env
+// or setFeedURL call is needed; electron-updater reads the bundled yml on first
+// checkForUpdates.
 function configureFeed(channel: UpdateChannel): void {
-	const { owner, name } = repo();
-	autoUpdater.setFeedURL({ provider: "github", owner, repo: name });
 	autoUpdater.channel = channel; // "latest" | "nightly"
 	autoUpdater.allowDowngrade = true; // permits a nightly -> stable channel switch
 }