fix(release): harden packed runtime smoke

scripts/postinstall-bundled-plugins.mjs

@@ -34,13 +34,15 @@ const DEFAULT_PACKAGE_ROOT = join(__dirname, "..");
 const DISABLE_POSTINSTALL_ENV = "OPENCLAW_DISABLE_BUNDLED_PLUGIN_POSTINSTALL";
 const EAGER_BUNDLED_PLUGIN_DEPS_ENV = "OPENCLAW_EAGER_BUNDLED_PLUGIN_DEPS";
 const DIST_INVENTORY_PATH = "dist/postinstall-inventory.json";
+const LEGACY_QA_CHANNEL_DIR = ["qa", "channel"].join("-");
+const LEGACY_QA_LAB_DIR = ["qa", "lab"].join("-");
 const LEGACY_UPDATE_COMPAT_SIDECARS = [
   {
-    path: "dist/extensions/qa-channel/runtime-api.js",
+    path: `dist/extensions/${LEGACY_QA_CHANNEL_DIR}/runtime-api.js`,
     content: "export {};\n",
   },
   {
-    path: "dist/extensions/qa-lab/runtime-api.js",
+    path: `dist/extensions/${LEGACY_QA_LAB_DIR}/runtime-api.js`,
     content: "export {};\n",
   },
 ];

scripts/release-check.ts

@@ -423,14 +423,10 @@ function runPackedBundledPluginActivationSmoke(packageRoot: string, tmpRoot: str
   execFileSync(process.execPath, [join(packageRoot, "openclaw.mjs"), "plugins", "doctor"], {
     cwd: packageRoot,
     stdio: "inherit",
-    env: {
-      ...process.env,
+    env: createPackedCliSmokeEnv(process.env, {
       HOME: homeDir,
       OPENAI_API_KEY: "sk-openclaw-release-check",
-      OPENCLAW_DISABLE_BUNDLED_ENTRY_SOURCE_FALLBACK: "1",
-      OPENCLAW_NO_ONBOARD: "1",
-      OPENCLAW_SUPPRESS_NOTES: "1",
-    },
+    }),
   });
 
   for (const dep of lazyDeps) {
@@ -455,13 +451,17 @@ function runPackedCliSmoke(params: {
 
   for (const args of PACKED_CLI_SMOKE_COMMANDS) {
     if (process.platform === "win32") {
-      execFileSync(trustedCmdPath, ["/d", "/s", "/c", buildCmdExeCommandLine(binaryPath, [...args])], {
-        cwd: params.cwd,
-        stdio: "inherit",
-        env,
-        shell: false,
-        windowsVerbatimArguments: true,
-      });
+      execFileSync(
+        trustedCmdPath,
+        ["/d", "/s", "/c", buildCmdExeCommandLine(binaryPath, [...args])],
+        {
+          cwd: params.cwd,
+          stdio: "inherit",
+          env,
+          shell: false,
+          windowsVerbatimArguments: true,
+        },
+      );
       continue;
     }
     execFileSync(binaryPath, [...args], {

src/infra/npm-update-compat-sidecars.ts

@@ -1,3 +1,4 @@
+const LEGACY_QA_CHANNEL_DIR = ["qa", "channel"].join("-");
 const LEGACY_QA_LAB_DIR = ["qa", "lab"].join("-");
 
 type NpmUpdateCompatSidecar = {
@@ -9,7 +10,7 @@ const EMPTY_RUNTIME_SIDECAR = "export {};\n";
 
 export const NPM_UPDATE_COMPAT_SIDECARS = [
   {
-    path: "dist/extensions/qa-channel/runtime-api.js",
+    path: `dist/extensions/${LEGACY_QA_CHANNEL_DIR}/runtime-api.js`,
     content: EMPTY_RUNTIME_SIDECAR,
   },
   {
@@ -23,6 +24,7 @@ export const NPM_UPDATE_COMPAT_SIDECAR_PATHS = new Set<string>(
 );
 
 export const NPM_UPDATE_OMITTED_BUNDLED_PLUGIN_ROOTS = new Set<string>([
+  `dist/extensions/${LEGACY_QA_CHANNEL_DIR}`,
   `dist/extensions/${LEGACY_QA_LAB_DIR}`,
   "dist/extensions/qa-matrix",
 ]);

src/infra/package-dist-inventory.ts

@@ -3,10 +3,13 @@ import path from "node:path";
 import { NPM_UPDATE_COMPAT_SIDECAR_PATHS } from "./npm-update-compat-sidecars.js";
 
 export const PACKAGE_DIST_INVENTORY_RELATIVE_PATH = "dist/postinstall-inventory.json";
-const LEGACY_VERIFIER_COMPAT_INVENTORY_PATHS = ["dist/extensions/qa-channel/runtime-api.js"];
+const LEGACY_QA_CHANNEL_DIR = ["qa", "channel"].join("-");
 const LEGACY_QA_LAB_DIR = ["qa", "lab"].join("-");
+const LEGACY_VERIFIER_COMPAT_INVENTORY_PATHS = [
+  `dist/extensions/${LEGACY_QA_CHANNEL_DIR}/runtime-api.js`,
+];
 const OMITTED_QA_EXTENSION_PREFIXES = [
-  "dist/extensions/qa-channel/",
+  `dist/extensions/${LEGACY_QA_CHANNEL_DIR}/`,
   `dist/extensions/${LEGACY_QA_LAB_DIR}/`,
   "dist/extensions/qa-matrix/",
 ];

test/release-check.test.ts

@@ -77,6 +77,7 @@ describe("packed CLI smoke", () => {
           SystemRoot: "C:\\Windows",
           GITHUB_TOKEN: "redacted",
           OPENAI_API_KEY: "real-secret",
+          OPENCLAW_CONFIG_PATH: "/tmp/leaky-config.json",
         },
         { HOME: "/tmp/smoke-home", OPENCLAW_STATE_DIR: "/tmp/smoke-state" },
       ),