Desktop crash reporting + diagnostics export (#961)

* Add crash reporting and one-click diagnostics export to the desktop app

- Sentry in the Electron main process, gated on a DSN baked in at build
  time (SENTRY_DSN env -> define). No DSN (local/dev/fork builds) means
  nothing is ever sent; native crash dumps are still written locally via
  crashReporter for the diagnostics export.
- Sidecar stdout/stderr now persist to main.log under a 'sidecar' scope
  (previously terminal-only, so server crashes left no trace on disk).
  Unexpected sidecar exits after a successful boot are logged and
  reported with a bounded stderr tail.
- render-process-gone / child-process-gone are logged locally and
  captured upstream; main-process uncaught errors land in main.log.
- Export Diagnostics: app menu item + Settings-page button pack a
  redacted manifest (version, OS, paths, port - never passwords or
  ~/.executor data), recent logs, and crash dumps into a zip in
  Downloads and reveal it in the file manager.
- publish-desktop.yml passes vars.SENTRY_DSN into the electron-vite
  build step.

* Extend desktop crash reporting to renderer and sidecar, add Report a Problem

- Renderer: the shared web bundle initializes browser error reporting
  only when the desktop preload bridge hands it a DSN at runtime —
  nothing is baked into the bundle, so executor web / self-host / cloud
  stay inert. Handled UI errors already route through reportError and
  are picked up by the global handlers.
- Sidecar: env-gated init in the sidecar entry (DSN passed by the main
  process, desktop-with-DSN builds only). Captures uncaught exceptions
  and unhandled rejections in the server process. The CLI never sets
  the env vars, keeping executor web telemetry-free.
- One runId per launch tags events from all three processes and is
  stamped into the diagnostics-zip manifest, so a user-sent zip and its
  Sentry events can be cross-referenced.
- electron-log lines become Sentry breadcrumbs (file transport hook),
  so events arrive with recent log context.
- 'Report a Problem…' menu item exports the diagnostics zip and opens
  a prefilled GitHub issue (version, OS, runId).

Verified against a local fake ingest server: session/event envelopes
received from all three SDKs (browser on boot, electron on forced
sidecar SIGKILL with breadcrumbs attached, bun on forced bind failure).
Compiled-sidecar smoke test passes with @sentry/bun bundled.

* Honor DO_NOT_TRACK, add sidecar crash screen, prove the flow on camera

- DO_NOT_TRACK=1 (or true) disables crash reporting in all three
  processes — checked once in the main process, which is the single
  source of the renderer's and sidecar's reporting config.
- When the sidecar dies under a live window the app now swaps the dead
  web UI for an in-window crash screen (data: URL, preload bridge
  intact) with Restart server / Export diagnostics actions. Restart
  drives the existing sidecar restart IPC and reloads the console.
- New e2e desktop target + scenario: launches the real Electron app in
  a throwaway HOME via Playwright's electron driver, SIGKILLs the
  sidecar, asserts the crash screen, recovers via its Restart button,
  and asserts the healed sidecar is a new pid. Produces session.mp4 +
  per-step screenshots under e2e/runs/desktop/. Run with
  `npm run test:desktop` in e2e/ (needs a display).

* Rename the desktop crash-report DSN variable to DESKTOP_SENTRY_DSN

Repo-level SENTRY_DSN was ambiguous next to cloud's own Sentry config;
the variable now names its surface.

* Crash screen can check for updates

A recurring sidecar crash may already be fixed upstream — the crash
screen gets a Check for updates button (reuses the menu update flow),
and showing the screen quietly stages any available update so the
install prompt appears on its own, mirroring the fatal-startup
self-heal.

Author: RhysSullivan

.github/workflows/publish-desktop.yml

@@ -107,6 +107,11 @@ jobs:
         working-directory: apps/desktop
 
       - name: Build Electron main/preload/renderer
+        env:
+          # Crash-report DSN baked into the main bundle (see the define in
+          # electron.vite.config.ts). Unset (forks, local) → crash reporting
+          # is compiled out and dumps stay local.
+          DESKTOP_SENTRY_DSN: ${{ vars.DESKTOP_SENTRY_DSN }}
         run: bunx --bun electron-vite build
         working-directory: apps/desktop
 

apps/desktop/electron.vite.config.ts

@@ -14,11 +14,18 @@ const ELECTRON_EXTERNALS = [
   "electron-store",
   "electron-updater",
   "electron-window-state",
+  "@sentry/electron",
+  "@sentry/electron/main",
 ];
 
 export default defineConfig({
   main: {
     plugins: [externalizeDepsPlugin()],
+    define: {
+      // Crash-report DSN baked in at build time (publish-desktop.yml).
+      // Empty in local/dev builds → Sentry stays fully disabled.
+      __EXECUTOR_SENTRY_DSN__: JSON.stringify(process.env.DESKTOP_SENTRY_DSN ?? ""),
+    },
     build: {
       rollupOptions: {
         input: { index: "src/main/index.ts" },

apps/desktop/package.json

@@ -21,6 +21,8 @@
     "typecheck:slow": "tsc --noEmit"
   },
   "dependencies": {
+    "@sentry/bun": "^10.57.0",
+    "@sentry/electron": "^7.13.0",
     "electron-log": "^5",
     "electron-store": "^10",
     "electron-updater": "^6",
@@ -41,6 +43,7 @@
     "@jitl/quickjs-wasmfile-release-sync": "catalog:",
     "@modelcontextprotocol/sdk": "^1.29.0",
     "@types/node": "catalog:",
+    "@zip.js/zip.js": "^2.8.26",
     "bun-types": "catalog:",
     "electron": "41.2.1",
     "electron-builder": "^26",

apps/desktop/src/main/crash-screen.ts

@@ -0,0 +1,97 @@
+/**
+ * In-window screen shown when the sidecar dies under a running window.
+ * Replaces the dead web UI (which would otherwise sit there failing every
+ * fetch) with an explanation and a recovery path. Rendered as a data: URL
+ * in the existing BrowserWindow, so the preload bridge stays available —
+ * the buttons drive the same `window.executor` IPC the settings page uses.
+ */
+
+export interface CrashScreenOptions {
+  /** Whether a crash report was sent upstream (DSN build, not opted out). */
+  readonly reported: boolean;
+}
+
+export const sidecarCrashHtml = ({ reported }: CrashScreenOptions): string => `<!doctype html>
+<html>
+  <head>
+    <meta charset="utf-8" />
+    <title>Executor</title>
+    <style>
+      :root { color-scheme: dark; }
+      body {
+        margin: 0;
+        min-height: 100vh;
+        display: grid;
+        place-items: center;
+        background: #0a0a0a;
+        color: #fafafa;
+        font-family: -apple-system, BlinkMacSystemFont, "Segoe UI", sans-serif;
+      }
+      .card { max-width: 26rem; padding: 2rem; text-align: center; }
+      .icon { font-size: 2rem; margin-bottom: 0.75rem; }
+      h1 { font-size: 1.15rem; font-weight: 600; margin: 0 0 0.5rem; }
+      p { font-size: 0.875rem; color: #a1a1aa; line-height: 1.5; margin: 0 0 1.5rem; }
+      .row { display: flex; gap: 0.6rem; justify-content: center; }
+      button {
+        padding: 0.55rem 1.1rem;
+        border-radius: 6px;
+        border: 1px solid transparent;
+        background: #fafafa;
+        color: #0a0a0a;
+        font: inherit;
+        font-size: 0.875rem;
+        cursor: pointer;
+        white-space: nowrap;
+      }
+      button.secondary { background: transparent; color: #fafafa; border-color: #3f3f46; }
+      #status { margin-top: 1.25rem; min-height: 1.2em; font-size: 0.8rem; color: #a1a1aa; }
+    </style>
+  </head>
+  <body>
+    <main class="card">
+      <div class="icon">&#9888;&#65039;</div>
+      <h1>The local Executor server stopped unexpectedly</h1>
+      <p>
+        Your data is safe.${reported ? " A crash report was sent automatically so this can get fixed." : ""}
+        Restart the server to keep working.
+      </p>
+      <div class="row">
+        <button id="restart">Restart server</button>
+        <button id="update" class="secondary">Check for updates</button>
+        <button id="export" class="secondary">Export diagnostics</button>
+      </div>
+      <p id="status"></p>
+    </main>
+    <script>
+      const status = document.getElementById("status");
+      document.getElementById("restart").addEventListener("click", async () => {
+        status.textContent = "Restarting\\u2026";
+        try {
+          // Main restarts the sidecar and reloads this window on success.
+          await window.executor.restartServer();
+        } catch {
+          status.textContent = "Restart failed \\u2014 try quitting and reopening Executor.";
+        }
+      });
+      document.getElementById("update").addEventListener("click", async () => {
+        status.textContent = "Checking for updates\\u2026";
+        try {
+          // Outcomes surface as native dialogs (install prompt / no updates).
+          await window.executor.checkForUpdates();
+          status.textContent = "";
+        } catch {
+          status.textContent = "Update check failed \\u2014 check your network.";
+        }
+      });
+      document.getElementById("export").addEventListener("click", async () => {
+        status.textContent = "Exporting\\u2026";
+        try {
+          await window.executor.exportDiagnostics();
+          status.textContent = "Diagnostics saved to Downloads.";
+        } catch {
+          status.textContent = "Export failed \\u2014 see the log file.";
+        }
+      });
+    </script>
+  </body>
+</html>`;