fix(distribute): stop bloating FLY_DISTRIBUTE_RESULTS env var (E2BIG)

src/distribute-core.ts

@@ -3,7 +3,11 @@
 import * as core from "@actions/core";
 import { HttpCodes, Headers, MediaTypes } from "@actions/http-client";
 import { createHttpClient, truncate } from "./utils";
-import { DistributeRequest, DistributeResponse } from "./types";
+import {
+  DistributeRequest,
+  DistributeResponse,
+  DistributeSummaryEntry,
+} from "./types";
 
 const REQUEST_TIMEOUT_MS = 30000;
 
@@ -90,7 +94,7 @@ export async function distributeArtifact(
  * stay consistent with the step log line (no drift between sources).
  */
 export function buildDockerPullCommand(
-  response: DistributeResponse,
+  response: DistributeSummaryEntry,
 ): string | null {
   if (response.package_type !== "docker") {
     return null;

src/distribute.spec.ts

@@ -26,13 +26,13 @@ vi.mock("./utils", () => ({
 }));
 
 import * as core from "@actions/core";
-import { runDistribute } from "./distribute";
+import { runDistribute, toSummaryEntry } from "./distribute";
 import {
   ENV_FLY_URL_RUNTIME,
   ENV_FLY_ACCESS_TOKEN_RUNTIME,
   ENV_FLY_DISTRIBUTE_RESULTS,
 } from "./constants";
-import type { DistributeResponse } from "./types";
+import type { DistributeResponse, DistributeSummaryEntry } from "./types";
 
 const MOCK_RESPONSE: DistributeResponse = {
   package_name: "my-app",
@@ -78,13 +78,15 @@ describe("runDistribute", () => {
     await runDistribute();
 
     expect(core.setFailed).not.toHaveBeenCalled();
+    // Step output keeps the full response (not subject to the env-var limit).
     expect(core.setOutput).toHaveBeenCalledWith(
       "results",
       JSON.stringify([MOCK_RESPONSE]),
     );
+    // Env var persists only the slim summary projection.
     expect(core.exportVariable).toHaveBeenCalledWith(
       ENV_FLY_DISTRIBUTE_RESULTS,
-      JSON.stringify([MOCK_RESPONSE]),
+      JSON.stringify([toSummaryEntry(MOCK_RESPONSE)]),
     );
     expect(mockDispose).toHaveBeenCalled();
   });
@@ -168,6 +170,16 @@ describe("runDistribute", () => {
     expect(core.info).toHaveBeenCalledWith(
       "   Pull:       docker pull flyjfrog.jfrog.io/docker-public/myorg/my-image:1.0.0",
     );
+    // Regression for issue #69: the unbounded `files[]` breakdown must NOT be
+    // persisted to the env var, otherwise FLY_DISTRIBUTE_RESULTS grows past the
+    // 128 KB single-env-var limit and breaks every later step.
+    const exported = vi
+      .mocked(core.exportVariable)
+      .mock.calls.find((c) => c[0] === ENV_FLY_DISTRIBUTE_RESULTS);
+    expect(exported).toBeDefined();
+    expect(exported![1]).not.toContain("files");
+    expect(exported![1]).not.toContain("manifest.json");
+    expect(exported![1]).toBe(JSON.stringify([toSummaryEntry(dockerResponse)]));
   });
 
   it("does not log a pull command for non-docker distributions", async () => {
@@ -217,7 +229,9 @@ describe("runDistribute", () => {
     const firstExport = vi.mocked(core.exportVariable).mock
       .calls[0] as unknown as [string, string];
     expect(firstExport[0]).toBe(ENV_FLY_DISTRIBUTE_RESULTS);
-    expect(firstExport[1]).toBe(JSON.stringify([MOCK_RESPONSE]));
+    expect(firstExport[1]).toBe(
+      JSON.stringify([toSummaryEntry(MOCK_RESPONSE)]),
+    );
     process.env[ENV_FLY_DISTRIBUTE_RESULTS] = firstExport[1];
 
     // Second invocation — env var already has the first line; appendDistributeResults
@@ -227,15 +241,15 @@ describe("runDistribute", () => {
     const secondExport = vi.mocked(core.exportVariable).mock
       .calls[1] as unknown as [string, string];
     expect(secondExport[0]).toBe(ENV_FLY_DISTRIBUTE_RESULTS);
-    const expected = `${JSON.stringify([MOCK_RESPONSE])}\n${JSON.stringify([response2])}`;
+    const expected = `${JSON.stringify([toSummaryEntry(MOCK_RESPONSE)])}\n${JSON.stringify([toSummaryEntry(response2)])}`;
     expect(secondExport[1]).toBe(expected);
 
     // Verify the post-step parser (same logic used by createJobSummary) handles
     // the accumulated newline-separated JSON arrays.
-    const parsed: DistributeResponse[] = secondExport[1]
+    const parsed: DistributeSummaryEntry[] = secondExport[1]
       .split("\n")
       .filter((line) => line.trim().length > 0)
-      .flatMap((line) => JSON.parse(line) as DistributeResponse[]);
+      .flatMap((line) => JSON.parse(line) as DistributeSummaryEntry[]);
     expect(parsed).toHaveLength(2);
     expect(parsed[0].package_name).toBe("my-app");
     expect(parsed[1].package_name).toBe("my-lib");

src/distribute.ts

@@ -11,7 +11,7 @@ import {
   ENV_FLY_DISTRIBUTE_RESULTS,
 } from "./constants";
 import { getErrorMessage } from "./utils";
-import { DistributeResponse } from "./types";
+import { DistributeResponse, DistributeSummaryEntry } from "./types";
 
 export async function runDistribute(): Promise<void> {
   try {
@@ -49,13 +49,24 @@ export async function runDistribute(): Promise<void> {
   }
 }
 
+/** Slim projection for the env var — see {@link DistributeSummaryEntry} / #69. */
+export function toSummaryEntry(r: DistributeResponse): DistributeSummaryEntry {
+  return {
+    package_name: r.package_name,
+    package_version: r.package_version,
+    package_type: r.package_type,
+    public_url: r.public_url,
+    download_url: r.download_url,
+  };
+}
+
 /**
- * Appends distribute results to the FLY_DISTRIBUTE_RESULTS env var as a
- * JSON line. The post step reads all accumulated lines to render the
- * distributed artifacts table in the job summary.
+ * Appends the slim distribute results to FLY_DISTRIBUTE_RESULTS as a JSON line;
+ * the post step reads all accumulated lines for the job-summary table. The full
+ * response is still exposed verbatim via the step `results` output.
  */
 function appendDistributeResults(results: DistributeResponse[]): void {
-  const line = JSON.stringify(results);
+  const line = JSON.stringify(results.map(toSummaryEntry));
   const existing = process.env[ENV_FLY_DISTRIBUTE_RESULTS] || "";
   const updated = existing ? `${existing}\n${line}` : line;
   core.exportVariable(ENV_FLY_DISTRIBUTE_RESULTS, updated);

src/job-summary.spec.ts

@@ -142,7 +142,7 @@ describe("createJobSummary", () => {
       version: "1.0.0",
       results: [
         { name: "app.zip", status: "success" },
-        { name: "app.tar.gz", status: "error", message: "checksum" },
+        { name: "app.tar.gz", status: "error" },
       ],
     };
     process.env[ENV_FLY_TRANSFER_RESULTS] = JSON.stringify(entry);
@@ -237,6 +237,41 @@ describe("createJobSummary", () => {
     expect(markdownContent).not.toContain("Distributed Artifacts");
   });
 
+  // Issue #69: the env var now carries only the slim summary projection
+  // (no `download_count`, no `files[]`). Verify the post step still renders a
+  // complete table — including the docker pull command — from that shape alone.
+  it("renders the distributed table from the slim env projection (no download_count/files)", async () => {
+    const slim = [
+      {
+        package_name: "my-app",
+        package_version: "1.0.0",
+        package_type: "generic",
+        public_url:
+          "https://fly.example.com/public/generic/tenant/my-app/1.0.0",
+        download_url:
+          "https://fly.example.com/public/generic/tenant/my-app/1.0.0/my-app.tar.gz",
+      },
+      {
+        package_name: "myorg/my-image",
+        package_version: "2.0.0",
+        package_type: "docker",
+        public_url: "https://flyjfrog.jfrog.io/v2/docker-public/myorg/my-image",
+        download_url:
+          "https://flyjfrog.jfrog.io/v2/docker-public/myorg/my-image/manifests/2.0.0",
+      },
+    ];
+    process.env[ENV_FLY_DISTRIBUTE_RESULTS] = JSON.stringify(slim);
+
+    await createJobSummary();
+
+    const markdownContent = mockSummary.addRaw.mock.calls[0][0] as string;
+    expect(markdownContent).toContain("### 🌐 Distributed Artifacts");
+    expect(markdownContent).toContain("my-app.tar.gz");
+    expect(markdownContent).toContain(
+      "docker pull flyjfrog.jfrog.io/docker-public/myorg/my-image:2.0.0",
+    );
+  });
+
   it("should render all rows when env var contains multiple newline-separated JSON arrays (multi-step accumulation)", async () => {
     const step1: DistributeResponse[] = [
       {
@@ -370,7 +405,7 @@ describe("buildTransfersTable", () => {
         version: "1.0",
         results: [
           { name: "ok.zip", status: "success" },
-          { name: "fail.zip", status: "error", message: "oops" },
+          { name: "fail.zip", status: "error" },
           { name: "other.zip", status: "configured" },
         ],
       },

src/job-summary.ts

@@ -5,7 +5,7 @@ import * as fs from "fs";
 import * as path from "path";
 import {
   CollectedArtifact,
-  DistributeResponse,
+  DistributeSummaryEntry,
   TransferSummaryEntry,
 } from "./types";
 import {
@@ -103,7 +103,9 @@ export function parseTransferResults(raw: string): TransferSummaryEntry[] {
     .map((line) => JSON.parse(line) as TransferSummaryEntry);
 }
 
-export function buildDistributedTable(results: DistributeResponse[]): string {
+export function buildDistributedTable(
+  results: DistributeSummaryEntry[],
+): string {
   if (results.length === 0) return "";
 
   const header = "| Package | Version | Download URL |\n| --- | --- | --- |";
@@ -121,7 +123,7 @@ export function buildDistributedTable(results: DistributeResponse[]): string {
  * OCI manifest JSON, which is useless to skim in a job summary — consumers
  * actually need a paste-ready pull command.
  */
-function renderDistributedDownloadCell(r: DistributeResponse): string {
+function renderDistributedDownloadCell(r: DistributeSummaryEntry): string {
   const pullCommand = buildDockerPullCommand(r);
   if (pullCommand) {
     return `\`${escPipe(pullCommand)}\``;
@@ -213,10 +215,10 @@ export async function createJobSummary(
     try {
       const distributedRaw = process.env[ENV_FLY_DISTRIBUTE_RESULTS] || "";
       if (distributedRaw.trim()) {
-        const allResults: DistributeResponse[] = distributedRaw
+        const allResults: DistributeSummaryEntry[] = distributedRaw
           .split("\n")
           .filter((line) => line.trim().length > 0)
-          .flatMap((line) => JSON.parse(line) as DistributeResponse[]);
+          .flatMap((line) => JSON.parse(line) as DistributeSummaryEntry[]);
         distributedTable = buildDistributedTable(allResults);
       }
     } catch (err) {

src/transfer.ts

@@ -206,14 +206,25 @@ export function resolveVersion(
  * Appends an upload/download result entry to the FLY_TRANSFER_RESULTS env var
  * as a JSON line. The post step reads all accumulated lines to render the
  * job summary. Each call adds one line for one sub-action invocation.
+ *
+ * Only the rendered fields (name + status) are persisted — see
+ * {@link TransferSummaryResult} / #69. `results[]` scales with file count, so
+ * dropping the unused `message` keeps the accumulated env var from drifting
+ * toward the 128 KB E2BIG wall. The full results (with `message`) are still
+ * exposed verbatim via the step `results` output.
  */
 export function appendTransferResults(
   type: "upload" | "download",
   name: string,
   version: string,
   results: FlyClientResult[],
 ): void {
-  const entry: TransferSummaryEntry = { type, name, version, results };
+  const entry: TransferSummaryEntry = {
+    type,
+    name,
+    version,
+    results: results.map((r) => ({ name: r.name, status: r.status })),
+  };
   const existing = process.env[ENV_FLY_TRANSFER_RESULTS] || "";
   const line = JSON.stringify(entry);
   const updated = existing ? `${existing}\n${line}` : line;

src/types.ts

@@ -82,6 +82,26 @@ export interface DistributeResponse {
   files?: DistributeResponseFile[];
 }
 
+/**
+ * Slim projection of {@link DistributeResponse} containing only the fields the
+ * job-summary "Distributed Artifacts" table renders. This is what gets
+ * persisted to the FLY_DISTRIBUTE_RESULTS env var across distribute steps.
+ *
+ * The full response carries an unbounded per-file `files[]` breakdown (plus
+ * `download_count`s) that the summary never reads. Persisting the full object
+ * grows the env var with every distribute call and can push it past the Linux
+ * single-env-var limit (MAX_ARG_STRLEN, 128 KB), which makes the kernel reject
+ * `execve` for every later step and post-cleanup with E2BIG. Keeping only the
+ * rendered fields bounds the per-entry size. See issue #69.
+ */
+export interface DistributeSummaryEntry {
+  package_name: string;
+  package_version: string;
+  package_type: string;
+  public_url: string;
+  download_url: string;
+}
+
 /**
  * JSON envelope written to stdout by every fly CLI command.
  * Mirrors Go type: client/internal/output/response.go → Response
@@ -101,6 +121,18 @@ export interface FlyClientResult {
   message?: string;
 }
 
+/**
+ * Slim per-file projection persisted in ENV_FLY_TRANSFER_RESULTS — only the
+ * fields the transfers table renders (name + status). `message` is dropped on
+ * purpose: the summary never shows it, and persisting it would grow the env var
+ * with every transferred file across steps, risking the same E2BIG failure as
+ * the distribute path (#69 / {@link DistributeSummaryEntry}).
+ */
+export interface TransferSummaryResult {
+  name: string;
+  status: FlyClientResult["status"];
+}
+
 /**
  * One upload or download invocation's results, accumulated in
  * ENV_FLY_TRANSFER_RESULTS as JSON-lines so the post step can
@@ -110,5 +142,5 @@ export interface TransferSummaryEntry {
   type: "upload" | "download";
   name: string;
   version: string;
-  results: FlyClientResult[];
+  results: TransferSummaryResult[];
 }