fix: harden setup tui handoff

src/tui/tui-launch.test.ts

@@ -0,0 +1,83 @@
+import type { ChildProcess, SpawnOptions } from "node:child_process";
+import { EventEmitter } from "node:events";
+import { afterEach, beforeEach, describe, expect, it, vi } from "vitest";
+
+const spawnMock = vi.hoisted(() => vi.fn());
+const detachMock = vi.hoisted(() => vi.fn());
+
+vi.mock("node:child_process", () => ({
+  spawn: spawnMock,
+}));
+
+vi.mock("../process/child-process-bridge.js", () => ({
+  attachChildProcessBridge: vi.fn(() => ({ detach: detachMock })),
+}));
+
+import { launchTuiCli } from "./tui-launch.js";
+
+const originalArgv = [...process.argv];
+const originalExecArgv = [...process.execArgv];
+
+function createChildProcess(): ChildProcess {
+  return new EventEmitter() as ChildProcess;
+}
+
+describe("launchTuiCli", () => {
+  beforeEach(() => {
+    process.argv = [...originalArgv];
+    process.argv[1] = "/repo/openclaw.mjs";
+    process.execArgv.length = 0;
+    spawnMock.mockReset();
+    detachMock.mockReset();
+    vi.spyOn(process.stdin, "pause").mockImplementation(() => process.stdin);
+    vi.spyOn(process.stdin, "resume").mockImplementation(() => process.stdin);
+    vi.spyOn(process.stdin, "isPaused").mockReturnValue(false);
+  });
+
+  afterEach(() => {
+    process.argv = [...originalArgv];
+    process.execArgv.length = 0;
+    process.execArgv.push(...originalExecArgv);
+    vi.restoreAllMocks();
+  });
+
+  it("filters inherited inspector flags when relaunching TUI", async () => {
+    process.execArgv.push(
+      "--import",
+      "tsx",
+      "--inspect=127.0.0.1:9229",
+      "--inspect-brk",
+      "--inspect-wait=0",
+      "--inspect-port",
+      "9230",
+      "--no-warnings",
+    );
+    const child = createChildProcess();
+    spawnMock.mockImplementation((_cmd: string, _args: string[], _opts: SpawnOptions) => {
+      queueMicrotask(() => child.emit("exit", 0, null));
+      return child;
+    });
+
+    await launchTuiCli({
+      url: "ws://127.0.0.1:18789",
+      token: "test-token",
+      deliver: false,
+    });
+
+    expect(spawnMock).toHaveBeenCalledWith(
+      process.execPath,
+      [
+        "--import",
+        "tsx",
+        "--no-warnings",
+        "/repo/openclaw.mjs",
+        "tui",
+        "--url",
+        "ws://127.0.0.1:18789",
+        "--token",
+        "test-token",
+      ],
+      expect.objectContaining({ stdio: "inherit" }),
+    );
+  });
+});

src/tui/tui-launch.ts

@@ -10,13 +10,42 @@ function appendOption(args: string[], flag: string, value: string | number | und
   args.push(flag, String(value));
 }
 
+function filterTuiExecArgv(execArgv: readonly string[]): string[] {
+  const filtered: string[] = [];
+  for (let index = 0; index < execArgv.length; index += 1) {
+    const arg = execArgv[index] ?? "";
+    if (
+      arg === "--inspect" ||
+      arg.startsWith("--inspect=") ||
+      arg === "--inspect-brk" ||
+      arg.startsWith("--inspect-brk=") ||
+      arg === "--inspect-wait" ||
+      arg.startsWith("--inspect-wait=")
+    ) {
+      continue;
+    }
+    if (arg === "--inspect-port") {
+      const next = execArgv[index + 1];
+      if (typeof next === "string" && !next.startsWith("-")) {
+        index += 1;
+      }
+      continue;
+    }
+    if (arg.startsWith("--inspect-port=")) {
+      continue;
+    }
+    filtered.push(arg);
+  }
+  return filtered;
+}
+
 function buildTuiCliArgs(opts: TuiOptions): string[] {
   const entry = process.argv[1]?.trim();
   if (!entry) {
     throw new Error("unable to relaunch TUI: current CLI entry path is unavailable");
   }
 
-  const args = [...process.execArgv, entry, "tui"];
+  const args = [...filterTuiExecArgv(process.execArgv), entry, "tui"];
   appendOption(args, "--url", opts.url);
   appendOption(args, "--token", opts.token);
   appendOption(args, "--password", opts.password);

src/wizard/setup.finalize.test.ts

@@ -5,6 +5,7 @@ import type { PluginWebSearchProviderEntry } from "../plugins/types.js";
 import type { RuntimeEnv } from "../runtime.js";
 
 const launchTuiCli = vi.hoisted(() => vi.fn(async () => {}));
+const restoreTerminalState = vi.hoisted(() => vi.fn());
 const probeGatewayReachable = vi.hoisted(() =>
   vi.fn<() => Promise<{ ok: boolean; detail?: string }>>(async () => ({ ok: true })),
 );
@@ -134,7 +135,7 @@ vi.mock("../infra/control-ui-assets.js", () => ({
 }));
 
 vi.mock("../terminal/restore.js", () => ({
-  restoreTerminalState: vi.fn(),
+  restoreTerminalState,
 }));
 
 vi.mock("../tui/tui-launch.js", () => ({
@@ -237,6 +238,7 @@ function createAdvancedFinalizeArgs(params: AdvancedFinalizeArgs = {}) {
 describe("finalizeSetupWizard", () => {
   beforeEach(() => {
     launchTuiCli.mockClear();
+    restoreTerminalState.mockClear();
     probeGatewayReachable.mockClear();
     waitForGatewayReachable.mockReset();
     waitForGatewayReachable.mockResolvedValue({ ok: true });
@@ -345,6 +347,50 @@ describe("finalizeSetupWizard", () => {
     );
   });
 
+  it("restores terminal state after failed TUI hatch", async () => {
+    launchTuiCli.mockRejectedValueOnce(new Error("TUI exited with code 1"));
+    const select = vi.fn(async (params: { message: string }) => {
+      if (params.message === "How do you want to hatch your bot?") {
+        return "tui";
+      }
+      return "later";
+    });
+    const prompter = buildWizardPrompter({ select: select as never });
+
+    await expect(
+      finalizeSetupWizard({
+        flow: "advanced",
+        opts: {
+          acceptRisk: true,
+          authChoice: "skip",
+          installDaemon: false,
+          skipHealth: true,
+          skipUi: false,
+        },
+        baseConfig: {},
+        nextConfig: {},
+        workspaceDir: "/tmp",
+        settings: {
+          port: 18789,
+          bind: "loopback",
+          authMode: "token",
+          gatewayToken: "test-token",
+          tailscaleMode: "off",
+          tailscaleResetOnExit: false,
+        },
+        prompter,
+        runtime: createRuntime(),
+      }),
+    ).rejects.toThrow("TUI exited with code 1");
+
+    expect(restoreTerminalState).toHaveBeenCalledWith("pre-setup tui", {
+      resumeStdinIfPaused: true,
+    });
+    expect(restoreTerminalState).toHaveBeenCalledWith("post-setup tui", {
+      resumeStdinIfPaused: true,
+    });
+  });
+
   it("does not persist resolved SecretRef token in daemon install plan", async () => {
     const prompter = buildWizardPrompter({
       select: vi.fn(async () => "later") as never,

src/wizard/setup.finalize.ts

@@ -423,15 +423,18 @@ export async function finalizeSetupWizard(
 
     if (hatchChoice === "tui") {
       restoreTerminalState("pre-setup tui", { resumeStdinIfPaused: true });
-      await launchTuiCli({
-        url: links.wsUrl,
-        token: settings.authMode === "token" ? settings.gatewayToken : undefined,
-        password: settings.authMode === "password" ? resolvedGatewayPassword : "",
-        // Safety: setup TUI should not auto-deliver to lastProvider/lastTo.
-        deliver: false,
-        message: hasBootstrap ? "Wake up, my friend!" : undefined,
-      });
-      restoreTerminalState("post-setup tui", { resumeStdinIfPaused: true });
+      try {
+        await launchTuiCli({
+          url: links.wsUrl,
+          token: settings.authMode === "token" ? settings.gatewayToken : undefined,
+          password: settings.authMode === "password" ? resolvedGatewayPassword : "",
+          // Safety: setup TUI should not auto-deliver to lastProvider/lastTo.
+          deliver: false,
+          message: hasBootstrap ? "Wake up, my friend!" : undefined,
+        });
+      } finally {
+        restoreTerminalState("post-setup tui", { resumeStdinIfPaused: true });
+      }
       launchedTui = true;
     } else if (hatchChoice === "web") {
       const browserSupport = await detectBrowserOpenSupport();