Merge pull request #93 from smart-mcp-proxy/fix/tray-startup-timeout-and-output-capture

Fix: Tray startup timeout and output capture race conditions

Author: Dumbris

cmd/mcpproxy-tray/internal/monitor/process.go

@@ -371,17 +371,31 @@ func (pm *ProcessMonitor) setupOutputCapture() error {
 		return fmt.Errorf("failed to create stderr pipe: %w", err)
 	}
 
+	// Use a WaitGroup to ensure capture goroutines are ready before starting process
+	var captureReady sync.WaitGroup
+	captureReady.Add(2) // stdout + stderr
+
 	// Start output capture goroutines
-	go pm.captureOutput(stdoutPipe, &pm.stdoutBuf, "stdout")
-	go pm.captureOutput(stderrPipe, &pm.stderrBuf, "stderr")
+	go pm.captureOutput(stdoutPipe, &pm.stdoutBuf, "stdout", &captureReady)
+	go pm.captureOutput(stderrPipe, &pm.stderrBuf, "stderr", &captureReady)
+
+	// Wait for both capture goroutines to be ready
+	captureReady.Wait()
+	pm.logger.Debug("Output capture goroutines ready")
 
 	return nil
 }
 
 // captureOutput captures output from a pipe
-func (pm *ProcessMonitor) captureOutput(pipe io.ReadCloser, buf *strings.Builder, streamName string) {
+func (pm *ProcessMonitor) captureOutput(pipe io.ReadCloser, buf *strings.Builder, streamName string, ready *sync.WaitGroup) {
 	defer pipe.Close()
 
+	// Signal that this goroutine is ready to read
+	if ready != nil {
+		pm.logger.Debug("Output capture goroutine starting", "stream", streamName)
+		ready.Done()
+	}
+
 	scanner := bufio.NewScanner(pipe)
 	for scanner.Scan() {
 		line := scanner.Text()

cmd/mcpproxy-tray/internal/state/states.go

@@ -106,7 +106,7 @@ type Info struct {
 
 // GetInfo returns metadata for a given state
 func GetInfo(state State) Info {
-	timeout30s := 30 * time.Second
+	timeout90s := 90 * time.Second  // Must exceed health monitor's readinessTimeout (60s)
 	timeout5s := 5 * time.Second
 	timeout10s := 10 * time.Second
 
@@ -127,7 +127,7 @@ func GetInfo(state State) Info {
 			Name:        StateWaitingForCore,
 			Description: "Waiting for core to become ready",
 			UserMessage: "Core starting up...",
-			Timeout:     &timeout30s,
+			Timeout:     &timeout90s,  // Increased to 90s to allow Docker isolation startup (health timeout is 60s)
 		},
 		StateConnectingAPI: {
 			Name:        StateConnectingAPI,