fix(sidecar/prepare-node): prefer process.execPath; reject shims#11
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v0.1.8's release tarball came out to 9.4 MB instead of the expected ~70 MB because prepare-node-binary.mjs bundled an 86 KB stub instead of the real Node binary. The script picked /opt/homebrew/bin/node on the macos-latest runner, which exists but appears to be a small launcher/shim rather than the full binary. Running the bundled sidecar would crash at startup with garbage from that file. Two complementary fixes: 1. Prefer `process.execPath` — the node interpreter actually running this script. It's by definition a real Node binary in the version the build expects. Especially reliable in CI where setup-node@v4 places node in a stable cache path and execPath resolves there. 2. Reject any candidate smaller than 10 MB with a warning. Real Node binaries are at least ~60 MB on macOS; anything in the hundreds of KB range is a shim and would produce a non-functional bundled node. Warn and skip rather than silently shipping garbage. Verified locally: now picks /usr/local/bin/node (process.execPath) and produces a 112.7 MB bundled node. The build would have shipped an 86 KB stub before this patch. Co-Authored-By: Claude Opus 4.7 <noreply@anthropic.com>
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Summary
v0.1.8's release tarball came out to 9.4 MB instead of the expected ~70 MB. Looking at the contents:
The bundled Node binary is an 86 KB stub. Running the sidecar would crash immediately when the bash stub tries to `exec` it.
Root cause
`sidecar/scripts/prepare-node-binary.mjs`'s `findSystemNode()` picks the first existing path from a static list: `/opt/homebrew/bin/node` → `/usr/local/bin/node` → `/opt/local/bin/node` → `command -v node`. On macos-latest GitHub runners, `/opt/homebrew/bin/node` exists but is a small launcher/shim, not the real binary. `existsSync()` returned true, `copyFileSync()` happily copied 86 KB.
Fix
Verified locally
```
source: /usr/local/bin/node
target arch: arm64 (rustc triple aarch64-apple-darwin)
prepared bundled node -> .../aos-mail-node-aarch64-apple-darwin (112.7 MB)
```
After merge
I'll move the v0.1.8 tag again. This is the last (we hope) issue blocking a working release.
🤖 Generated with Claude Code