From bed24721219a6a99066e09bad2b92739c0651f87 Mon Sep 17 00:00:00 2001
From: Peter Steinberger <steipete@gmail.com>
Date: Tue, 21 Apr 2026 03:45:21 +0100
Subject: [PATCH] fix: stabilize docker live checks

---
 scripts/docker/install-sh-nonroot/Dockerfile  |  1 +
 scripts/docker/install-sh-smoke/run.sh        |  2 +-
 .../gateway-models.profiles.live.test.ts      | 13 +++++++++
 src/terminal/note.ts                          | 28 +++++++++++++++++--
 src/terminal/table.test.ts                    | 10 ++++++-
 5 files changed, 50 insertions(+), 4 deletions(-)

diff --git a/scripts/docker/install-sh-nonroot/Dockerfile b/scripts/docker/install-sh-nonroot/Dockerfile
index 0c41ef8a938..ab3f7e9a97f 100644
--- a/scripts/docker/install-sh-nonroot/Dockerfile
+++ b/scripts/docker/install-sh-nonroot/Dockerfile
@@ -39,6 +39,7 @@ WORKDIR /home/app
 
 ENV NPM_CONFIG_FUND=false
 ENV NPM_CONFIG_AUDIT=false
+ENV NPM_CONFIG_UPDATE_NOTIFIER=false
 
 COPY install-sh-common/cli-verify.sh /usr/local/install-sh-common/cli-verify.sh
 COPY install-sh-common/version-parse.sh /usr/local/install-sh-common/version-parse.sh
diff --git a/scripts/docker/install-sh-smoke/run.sh b/scripts/docker/install-sh-smoke/run.sh
index a48236deb4d..3205a1b4713 100755
--- a/scripts/docker/install-sh-smoke/run.sh
+++ b/scripts/docker/install-sh-smoke/run.sh
@@ -14,7 +14,7 @@ UPDATE_BASELINE_TAG_URL="${OPENCLAW_INSTALL_UPDATE_BASELINE_TAG_URL:-}"
 UPDATE_EXPECT_VERSION="${OPENCLAW_INSTALL_UPDATE_EXPECT_VERSION:-}"
 UPDATE_TAG_URL="${OPENCLAW_INSTALL_UPDATE_TAG_URL:-}"
 HEARTBEAT_INTERVAL="${OPENCLAW_INSTALL_SMOKE_HEARTBEAT_INTERVAL:-60}"
-INSTALL_COMMAND_TIMEOUT="${OPENCLAW_INSTALL_SMOKE_COMMAND_TIMEOUT:-300}"
+INSTALL_COMMAND_TIMEOUT="${OPENCLAW_INSTALL_SMOKE_COMMAND_TIMEOUT:-900}"
 SCRIPT_DIR="$(cd "$(dirname "$0")" && pwd)"
 
 # shellcheck source=../install-sh-common/cli-verify.sh
diff --git a/src/gateway/gateway-models.profiles.live.test.ts b/src/gateway/gateway-models.profiles.live.test.ts
index 3fa22cf1ffa..dad70ddb8e8 100644
--- a/src/gateway/gateway-models.profiles.live.test.ts
+++ b/src/gateway/gateway-models.profiles.live.test.ts
@@ -1373,6 +1373,19 @@ async function runGatewayModelSuite(params: GatewayModelSuiteParams) {
 
   const workspaceDir = resolveAgentWorkspaceDir(params.cfg, agentId);
   await fs.mkdir(workspaceDir, { recursive: true });
+  await fs.mkdir(path.join(workspaceDir, ".openclaw"), { recursive: true });
+  await fs.writeFile(
+    path.join(workspaceDir, ".openclaw", "workspace-state.json"),
+    `${JSON.stringify(
+      {
+        version: 1,
+        setupCompletedAt: new Date().toISOString(),
+      },
+      null,
+      2,
+    )}\n`,
+  );
+  await fs.rm(path.join(workspaceDir, "BOOTSTRAP.md"), { force: true });
   const nonceA = randomUUID();
   const nonceB = randomUUID();
   const toolProbePath = path.join(workspaceDir, `.openclaw-live-tool-probe.${nonceA}.txt`);
diff --git a/src/terminal/note.ts b/src/terminal/note.ts
index 06fc7f48186..0978f32770c 100644
--- a/src/terminal/note.ts
+++ b/src/terminal/note.ts
@@ -3,6 +3,7 @@ import { normalizeLowercaseStringOrEmpty } from "../shared/string-coerce.js";
 import { visibleWidth } from "./ansi.js";
 import { stylePromptTitle } from "./prompt-style.js";
 
+const MIN_NOTE_COLUMNS = 80;
 const URL_PREFIX_RE = /^(https?:\/\/|file:\/\/)/i;
 const WINDOWS_DRIVE_RE = /^[a-zA-Z]:[\\/]/;
 const FILE_LIKE_RE = /^[a-zA-Z0-9._-]+$/;
@@ -150,7 +151,7 @@ export function wrapNoteMessage(
   message: string,
   options: { maxWidth?: number; columns?: number } = {},
 ): string {
-  const columns = options.columns ?? process.stdout.columns ?? 80;
+  const columns = options.columns ?? resolveNoteColumns(process.stdout.columns);
   const maxWidth = options.maxWidth ?? Math.max(40, Math.min(88, columns - 10));
   return message
     .split("\n")
@@ -158,9 +159,32 @@ export function wrapNoteMessage(
     .join("\n");
 }
 
+export function resolveNoteColumns(columns: number | undefined): number {
+  if (!Number.isFinite(columns) || !columns || columns < MIN_NOTE_COLUMNS) {
+    return MIN_NOTE_COLUMNS;
+  }
+  return columns;
+}
+
+function createNoteOutput(columns: number): NodeJS.WriteStream {
+  if (process.stdout.columns === columns) {
+    return process.stdout;
+  }
+  const output = Object.create(process.stdout) as NodeJS.WriteStream;
+  Object.defineProperty(output, "columns", {
+    value: columns,
+    configurable: true,
+  });
+  output.write = process.stdout.write.bind(process.stdout);
+  return output;
+}
+
 export function note(message: string, title?: string) {
   if (isSuppressedByEnv(process.env.OPENCLAW_SUPPRESS_NOTES)) {
     return;
   }
-  clackNote(wrapNoteMessage(message), stylePromptTitle(title));
+  const columns = resolveNoteColumns(process.stdout.columns);
+  clackNote(wrapNoteMessage(message, { columns }), stylePromptTitle(title), {
+    output: createNoteOutput(columns),
+  });
 }
diff --git a/src/terminal/table.test.ts b/src/terminal/table.test.ts
index bad2fe48cf2..dae19b0faaf 100644
--- a/src/terminal/table.test.ts
+++ b/src/terminal/table.test.ts
@@ -1,6 +1,6 @@
 import { afterEach, describe, expect, it, vi } from "vitest";
 import { visibleWidth } from "./ansi.js";
-import { wrapNoteMessage } from "./note.js";
+import { resolveNoteColumns, wrapNoteMessage } from "./note.js";
 import { renderTable } from "./table.js";
 
 describe("renderTable", () => {
@@ -270,4 +270,12 @@ describe("wrapNoteMessage", () => {
     const wrapped = wrapNoteMessage(input, { maxWidth: 12, columns: 80 });
     expect(wrapped).toBe(input);
   });
+
+  it("clamps bogus TTY columns before clack wraps note text", () => {
+    expect(resolveNoteColumns(undefined)).toBe(80);
+    expect(resolveNoteColumns(0)).toBe(80);
+    expect(resolveNoteColumns(1)).toBe(80);
+    expect(resolveNoteColumns(79)).toBe(80);
+    expect(resolveNoteColumns(120)).toBe(120);
+  });
 });