fix: end-to-end working after laptop integration test

Discovered during smoke-testing on hzhang's laptop:

1. `--channels server:X --dangerously-load-development-channels server:X`
   makes Claude Code list the channel twice and the second copy never
   inherits dev-mode, leaving "server: entries need
   --dangerously-load-development-channels" stuck in the status panel.
   Fix: pass channel ONLY via --dangerously-load-development-channels.

2. Without a controlling TTY, Claude Code's dev-mode confirmation dialog
   blocks forever waiting for keystrokes that never arrive. Fix: spawn
   claude wrapped in `script -q -c CMD PTYLOG` so it gets a PTY, then
   write "\r" to stdin at several timeouts (cheap to over-send).

3. process-manager.markReady was matching on PID, but the PID in the
   bridge hello frame is the ClaudePlugin (bun) process's pid, not the
   script-wrapped claude process's pid we tracked. Fix: match on
   openclaw-session-key, which is consistent on both sides.

4. First spawn for a new session can't use --resume (no transcript exists
   yet) — claude errors out. Fix: probe
   ~/.claude/projects/<workspace-slug>/<uuid>.jsonl for existence and use
   --session-id on fresh sessions, --resume after a process restart.

5. Add --debug-file per session so future debugging has the gating logs.

6. Local definePluginEntry shim (no openclaw runtime dependency) so
   `bun index.ts` works standalone for laptop smoke tests.

End-to-end verified twice on laptop: curl POST -> SSE delta with the
exact reply text. Average cold-start ~10s, hot path 2-3s.

core/process-manager.ts

@@ -1,4 +1,7 @@
 import { spawn, type ChildProcess } from 'node:child_process'
+import { existsSync } from 'node:fs'
+import { join } from 'node:path'
+import { homedir } from 'node:os'
 import type { SynthesisConfig } from './config.js'
 import type { SessionMapping } from './session-mapping.js'
 
@@ -78,14 +81,10 @@ export class ProcessManager {
     return handle
   }
 
-  /** Bridge server calls this when it sees a `hello` frame matching this pid. */
-  markReady(pid: number): void {
-    for (const h of this.byKey.values()) {
-      if (h.pid === pid) {
-        h.markReady()
-        return
-      }
-    }
+  /** Bridge server calls this when it sees a `hello` frame for this session. */
+  markReady(openclawSessionKey: string): void {
+    const h = this.byKey.get(openclawSessionKey)
+    if (h) h.markReady()
   }
 
   touch(openclawSessionKey: string): void {
@@ -97,36 +96,59 @@ export class ProcessManager {
     const { config } = this.deps
     const wsUrl = `ws://127.0.0.1:${config.channelWsPort}/bridge`
     const channelTag = `server:${config.channelName}`
+    // First spawn for this session-id uses --session-id (fresh); subsequent
+    // spawns (after idle reap / OOM / crash) use --resume to pick up the
+    // saved transcript at ~/.claude/projects/<workspace-slug>/<uuid>.jsonl.
+    const hasExistingSession = claudeSessionFileExists(workspace, claudeSessionUuid)
+    const sessionFlag = hasExistingSession
+      ? ['--resume', claudeSessionUuid]
+      : ['--session-id', claudeSessionUuid]
+    // Pass channel ONLY via --dangerously-load-development-channels.
+    // Passing the same channel through both --channels and
+    // --dangerously-load-development-channels makes Claude Code list it
+    // twice ("Listening for channel messages from: X, X") and the second
+    // entry never inherits the dev-mode flag — the status panel ends up
+    // saying "server: entries need --dangerously-load-development-channels"
+    // even after the dev-mode confirmation. The dev flag implies the
+    // channel is loaded, so --channels is redundant here.
+    const debugFile = `/tmp/synthesis-claude-${openclawSessionKey.replace(/[^a-z0-9]/gi, '_')}.debug.log`
     const args = [
-      '--channels', channelTag,
       '--dangerously-load-development-channels', channelTag,
-      '--resume', claudeSessionUuid,
+      ...sessionFlag,
       '--permission-mode', config.permissionMode,
+      '--debug-file', debugFile,
     ]
 
     this.log.info(`spawning claude session=${openclawSessionKey} claude_uuid=${claudeSessionUuid} workspace=${workspace}`)
 
-    const proc = spawn('claude', args, {
+    // Wrap claude in `script(1)` to give it a PTY. Without a TTY, Claude
+    // Code's interactive prompts (workspace-trust, dev-channels confirm)
+    // block forever waiting for keystrokes that never arrive. `script -q -c`
+    // forks a PTY, runs the command inside it, and discards the transcript
+    // to /dev/null. Stdin we write to is the PTY master.
+    const claudeCmd = ['claude', ...args].map(a => /[\s"]/.test(a) ? `"${a.replace(/"/g, '\\"')}"` : a).join(' ')
+    const ptyLog = `/tmp/synthesis-claude-${openclawSessionKey.replace(/[^a-z0-9]/gi, '_')}.pty`
+    const proc = spawn('script', ['-q', '-c', claudeCmd, ptyLog], {
       cwd: workspace,
       env: {
         ...process.env,
         SYNTHESIS_WS_URL: wsUrl,
         SYNTHESIS_OPENCLAW_SESSION: openclawSessionKey,
         SYNTHESIS_CLAUDE_SESSION: claudeSessionUuid,
+        TERM: 'xterm-256color',
       },
       stdio: ['pipe', 'pipe', 'pipe'],
       detached: false,
     })
 
-    // After ~500ms, send "1\n" to confirm the dev-channels dialog. Idempotent
-    // if the dialog isn't there (claude eats the keystroke harmlessly).
+    // Pre-feed Enter keystrokes through the PTY to dismiss any startup
+    // prompts (dev-channels confirm; trusted-workspace if anything slipped
+    // through). Cheap to over-send — Claude eats unexpected keystrokes.
+    for (const delay of [800, 1500, 2500, 4000, 6000]) {
       setTimeout(() => {
-      try {
-        proc.stdin?.write('1\n')
-      } catch {
-        /* ignore */
+        try { proc.stdin?.write('\r') } catch { /* ignore */ }
+      }, delay)
     }
-    }, 500)
 
     let resolveReady!: () => void
     const ready = new Promise<void>(r => { resolveReady = r })
@@ -181,6 +203,11 @@ export class ProcessManager {
     return [...this.byKey.values()]
   }
 
+  /** Async helper exposed for tests / admin tools. */
+  static sessionFileExists(workspace: string, uuid: string): boolean {
+    return claudeSessionFileExists(workspace, uuid)
+  }
+
   async shutdown(): Promise<void> {
     this.shuttingDown = true
     if (this.idleSweeper) clearInterval(this.idleSweeper)
@@ -190,3 +217,18 @@ export class ProcessManager {
     this.byKey.clear()
   }
 }
+
+/**
+ * Claude Code persists session transcripts at:
+ *   ~/.claude/projects/<workspace-slug>/<session-uuid>.jsonl
+ * where workspace-slug is the absolute workspace path with `/` → `-`.
+ */
+function claudeSessionFileExists(workspace: string, uuid: string): boolean {
+  try {
+    const slug = workspace.replace(/\//g, '-')
+    const path = join(homedir(), '.claude', 'projects', slug, `${uuid}.jsonl`)
+    return existsSync(path)
+  } catch {
+    return false
+  }
+}

index.ts

@@ -1,5 +1,12 @@
-import { definePluginEntry } from 'openclaw/plugin-sdk/plugin-entry'
-import type { OpenClawPluginApi } from 'openclaw/plugin-sdk/core'
+// Local `definePluginEntry` shim. The OpenClaw plugin runtime evaluates this
+// module and calls .register() on the default export — it doesn't care where
+// definePluginEntry came from. Defining it locally lets us run standalone
+// (`bun index.ts`) without the `openclaw` package installed.
+function definePluginEntry<T extends { id: string; name: string; description?: string; register: (api: any) => void | Promise<void> }>(opts: T): T {
+  return opts
+}
+type OpenClawPluginApi = unknown
+
 import fs from 'node:fs'
 import path from 'node:path'
 import { normalizeConfig, type SynthesisConfig } from './core/config.js'

web/bridge-server.ts

@@ -70,7 +70,7 @@ export function startBridgeServer(deps: BridgeDeps): { httpServer: http.Server;
         const prev = byKey.get(conn.openclawSessionKey)
         if (prev && prev.ws !== ws) try { prev.ws.close(4002, 'replaced by reconnect') } catch {}
         byKey.set(conn.openclawSessionKey, conn)
-        processManager.markReady(conn.pid)
+        processManager.markReady(conn.openclawSessionKey)
         log.info(`hello session=${conn.openclawSessionKey} pid=${conn.pid}`)
         ws.send(JSON.stringify({ type: 'hello_ack' }))
         return
@@ -123,6 +123,7 @@ export function startBridgeServer(deps: BridgeDeps): { httpServer: http.Server;
 
   // ── HTTP server (OpenAI-compatible /v1/chat/completions) ────────────────────
   const httpServer = http.createServer(async (req, res) => {
+    log.info(`[trace] http req method=${req.method} url=${req.url}`)
     if (req.method === 'GET' && req.url === '/health') {
       res.writeHead(200, { 'Content-Type': 'application/json' })
       res.end(JSON.stringify({ ok: true, processes: processManager.list().length, conns: byKey.size }))
@@ -132,14 +133,24 @@ export function startBridgeServer(deps: BridgeDeps): { httpServer: http.Server;
       res.writeHead(404); res.end(); return
     }
 
-    let bodyRaw = ''
-    req.on('data', c => { bodyRaw += c })
-    req.on('end', async () => {
+    // Read the body synchronously (Promise-wrapped) so the outer `async`
+    // handler holds the response open until we explicitly end it. Returning
+    // from the outer fn before res.end() causes Bun's http server to close
+    // the connection.
+    const bodyRaw = await new Promise<string>(resolve => {
+      let buf = ''
+      req.on('data', c => { buf += c })
+      req.on('end', () => resolve(buf))
+    })
+
+    log.info(`[trace] body received bytes=${bodyRaw.length}`)
     let body: any
-      try { body = JSON.parse(bodyRaw) } catch {
+    try { body = JSON.parse(bodyRaw); log.info(`[trace] body parsed`) } catch (e) {
+      log.warn(`[trace] body parse FAILED: ${e}`)
       res.writeHead(400, { 'Content-Type': 'application/json' })
       res.end(JSON.stringify({ error: 'invalid_json' })); return
     }
+    {
 
       // Minimal session-key extraction for v1 — use headers where OpenClaw
       // doesn't natively send them. Production OpenClaw runtime injects
@@ -159,12 +170,19 @@ export function startBridgeServer(deps: BridgeDeps): { httpServer: http.Server;
       }
 
       const completionId = `chatcmpl-synthesis-${randomUUID().slice(0, 8)}`
+      log.info(`[trace] before writeHead session=${sessionKey} user=${latestUser.substring(0,50)}`)
+      try {
         res.writeHead(200, {
           'Content-Type': 'text/event-stream',
           'Cache-Control': 'no-cache',
           'Connection': 'keep-alive',
           'Transfer-Encoding': 'chunked',
         })
+        log.info(`[trace] after writeHead`)
+      } catch (e) {
+        log.warn(`[trace] writeHead FAILED: ${e}`)
+        return
+      }
 
       // SSE heartbeat: empty content delta every HEARTBEAT_MS to keep
       // OpenClaw's LLM idle watchdog from firing during long quiet turns.
@@ -215,7 +233,7 @@ export function startBridgeServer(deps: BridgeDeps): { httpServer: http.Server;
         clearInterval(sseHeartbeat)
         releaseSlot()
       }
-    })
+    }
   })
 
   httpServer.listen(config.bridgePort, '127.0.0.1', () => {