fix(ci): reformat generated ProcessEnv union to eliminate recurring merge conflicts

.gitignore

@@ -35,3 +35,4 @@ coverage/
 site/.vitepress/cache/
 !migrations/*.sql
 apps/gittensory-ui/public/downloads/gittensory-extension.zip
+.worker-configuration.gen-check.d.ts

package.json

@@ -21,8 +21,8 @@
     "command-reference:check": "node scripts/gen-command-reference.mjs --check",
     "selfhost:validate-observability": "node scripts/validate-observability-configs.mjs",
     "selfhost:config-lint": "tsx scripts/gittensory-config-lint.ts",
-    "cf-typegen": "wrangler types && perl -pi -e 's/[[:blank:]]+$//' worker-configuration.d.ts",
-    "cf-typegen:check": "wrangler types --check",
+    "cf-typegen": "node scripts/gen-cf-typegen.mjs",
+    "cf-typegen:check": "node scripts/gen-cf-typegen.mjs --check",
     "db:migrate:local": "wrangler d1 migrations apply gittensory --local",
     "db:migrate:remote": "wrangler d1 migrations apply gittensory --remote",
     "drizzle:generate": "drizzle-kit generate",

scripts/gen-cf-typegen.d.mts

@@ -0,0 +1,5 @@
+export const OUTPUT_PATH: string;
+
+export function formatCfTypegenOutput(source: string): string;
+
+export function genCfTypegen(options?: { check?: boolean }): { changed: boolean | undefined };

scripts/gen-cf-typegen.mjs

@@ -0,0 +1,72 @@
+#!/usr/bin/env node
+import { execFileSync } from "node:child_process";
+import { existsSync, readFileSync, unlinkSync, writeFileSync } from "node:fs";
+import { pathToFileURL } from "node:url";
+
+// Cloudflare's own `wrangler types` output packs every declared env var into ONE long single-line
+// `Pick<Cloudflare.Env, "A" | "B" | ...>>` union (the generated ProcessEnv interface). Two independent PRs
+// that each add a DIFFERENT new var to wrangler.jsonc's `vars` regenerate that SAME line with their own
+// insertion -- git's line-based 3-way merge sees "the same line changed differently in both branches" and
+// reports a conflict on worker-configuration.d.ts, even though the two additions are logically unrelated
+// (hit repeatedly across the #1667 incident-followup PRs). This wrapper still regenerates via the real
+// `wrangler types` CLI (so it can never drift from wrangler's own output), then reformats JUST that one
+// union onto one sorted entry per line -- two PRs adding different vars now land on different, non-adjacent
+// lines and merge cleanly like every other interface body in this file already does.
+export const OUTPUT_PATH = "worker-configuration.d.ts";
+const TEMP_PATH = ".worker-configuration.gen-check.d.ts";
+const PICK_RE = /Pick<Cloudflare\.Env, ((?:"[^"]+" \| )*"[^"]+")>>/;
+
+/** Pure: strip trailing whitespace (wrangler's own raw output convention this repo has always normalized),
+ *  normalize wrangler's own "Generated by ... running `wrangler types [path]`" header comment (it echoes
+ *  whatever path argument was passed, which check mode intentionally sets to a different temp path than
+ *  the real OUTPUT_PATH — without this, check mode would always report false staleness on that line alone),
+ *  then reformat the single-line ProcessEnv Pick<Cloudflare.Env, ...> union into one sorted entry per line. */
+export function formatCfTypegenOutput(source) {
+  const stripped = source
+    .replace(/[ \t]+$/gm, "")
+    .replace(/(Generated by Wrangler by running `wrangler types)[^`]*`/, "$1`");
+  const match = stripped.match(PICK_RE);
+  if (!match) {
+    throw new Error(`Could not find the ProcessEnv Pick<Cloudflare.Env, ...> union in the generated output to reformat.`);
+  }
+  const keys = match[1]
+    .split(" | ")
+    .map((quoted) => quoted.slice(1, -1))
+    .sort((a, b) => a.localeCompare(b));
+  const lines = keys.map((key) => `\t\t| "${key}"`).join("\n");
+  return stripped.replace(PICK_RE, `Pick<Cloudflare.Env,\n${lines}\n\t>>`);
+}
+
+export function genCfTypegen({ check = false } = {}) {
+  const target = check ? TEMP_PATH : OUTPUT_PATH;
+  try {
+    execFileSync("wrangler", ["types", target], { stdio: "inherit" });
+    const generated = formatCfTypegenOutput(readFileSync(target, "utf8"));
+    if (!check) {
+      writeFileSync(OUTPUT_PATH, generated);
+      return { changed: undefined };
+    }
+    const current = readFileSync(OUTPUT_PATH, "utf8");
+    return { changed: current !== generated };
+  } finally {
+    if (check && existsSync(TEMP_PATH)) unlinkSync(TEMP_PATH);
+  }
+}
+
+function main(argv) {
+  const check = argv.includes("--check");
+  const { changed } = genCfTypegen({ check });
+  if (check) {
+    if (changed) {
+      process.stderr.write(`gen-cf-typegen: ${OUTPUT_PATH} is stale; run npm run cf-typegen.\n`);
+      process.exit(1);
+    }
+    process.stdout.write(`gen-cf-typegen: ${OUTPUT_PATH} is up to date.\n`);
+    return;
+  }
+  process.stdout.write(`gen-cf-typegen: wrote ${OUTPUT_PATH}.\n`);
+}
+
+if (import.meta.url === pathToFileURL(process.argv[1] ?? "").href) {
+  main(process.argv.slice(2));
+}

test/unit/ci-cf-typegen-check.test.ts

@@ -30,7 +30,7 @@ describe("cf-typegen staleness guard (#2557)", () => {
     const pkg = record(JSON.parse(readFileSync("package.json", "utf8")), "package.json");
     const scripts = record(pkg.scripts, "package.json.scripts");
 
-    expect(scripts["cf-typegen:check"]).toBe("wrangler types --check");
+    expect(scripts["cf-typegen:check"]).toBe("node scripts/gen-cf-typegen.mjs --check");
     expect(String(scripts["test:ci"])).toContain("npm run cf-typegen:check");
     // Must run before typecheck, mirroring db:migrations:check's position -- a drift-check failure should
     // surface before the more expensive type/test/build steps run.

test/unit/ci-cf-typegen.test.ts

@@ -0,0 +1,107 @@
+import { execFileSync } from "node:child_process";
+import { mkdtempSync, rmSync, writeFileSync } from "node:fs";
+import { tmpdir } from "node:os";
+import { join } from "node:path";
+import { describe, expect, it } from "vitest";
+import { formatCfTypegenOutput } from "../../scripts/gen-cf-typegen.mjs";
+
+// #1667-followup: wrangler's own `wrangler types` output packs every declared env var into ONE long
+// single-line `Pick<Cloudflare.Env, "A" | "B" | ...>>` union. Two independent PRs that each add a DIFFERENT
+// new var regenerate that SAME line with their own insertion -- git's line-based 3-way merge sees "the same
+// line changed differently in both branches" and reports a real merge conflict on worker-configuration.d.ts,
+// even though the two additions are logically unrelated. This hit several same-day PRs in a row. The fix:
+// reformat that one union onto one sorted entry per line, so two independent additions land on different,
+// non-adjacent lines and merge cleanly like every other interface body in this file already does.
+function rawFixture(vars: string[]): string {
+  const union = vars.map((v) => `"${v}"`).join(" | ");
+  return [
+    "/* eslint-disable */",
+    "// Generated by Wrangler by running `wrangler types` (hash: deadbeef)",
+    "// Runtime types generated with workerd@1.0.0 2026-01-01 nodejs_compat",
+    "interface Env {}",
+    "declare namespace NodeJS {",
+    `\tinterface ProcessEnv extends StringifyValues<Pick<Cloudflare.Env, ${union}>> {}`,
+    "}",
+    "",
+  ].join("\n");
+}
+
+describe("gen-cf-typegen: formatCfTypegenOutput", () => {
+  it("reformats the single-line Pick<Cloudflare.Env, ...> union into one sorted entry per line", () => {
+    const out = formatCfTypegenOutput(rawFixture(["ZEBRA", "ALPHA", "MID"]));
+    expect(out).toContain('Pick<Cloudflare.Env,\n\t\t| "ALPHA"\n\t\t| "MID"\n\t\t| "ZEBRA"\n\t>>');
+  });
+
+  it("sorts regardless of the original declaration order", () => {
+    const outAsc = formatCfTypegenOutput(rawFixture(["A", "B", "C"]));
+    const outDesc = formatCfTypegenOutput(rawFixture(["C", "B", "A"]));
+    expect(outAsc).toBe(outDesc);
+  });
+
+  it("normalizes the wrangler header's echoed path argument so a different invocation path does not read as a content change", () => {
+    const bare = formatCfTypegenOutput(rawFixture(["A"]));
+    const withPath = formatCfTypegenOutput(rawFixture(["A"]).replace("wrangler types` (hash", "wrangler types .some-temp-path.d.ts` (hash"));
+    expect(bare).toBe(withPath);
+  });
+
+  it("strips trailing whitespace from every line", () => {
+    const withTrailingWhitespace = rawFixture(["A"]).replace("interface Env {}", "interface Env {}   ");
+    const out = formatCfTypegenOutput(withTrailingWhitespace);
+    expect(out).not.toMatch(/ +\n/);
+    expect(out).toContain("interface Env {}\n");
+  });
+
+  it("throws when the ProcessEnv Pick<Cloudflare.Env, ...> union is not found", () => {
+    expect(() => formatCfTypegenOutput("interface Env {}\n")).toThrow(/Could not find the ProcessEnv/);
+  });
+
+  it("REGRESSION: two independent single-var additions no longer conflict under a real git 3-way merge", () => {
+    const dir = mkdtempSync(join(tmpdir(), "cf-typegen-merge-"));
+    try {
+      const base = formatCfTypegenOutput(rawFixture(["ALPHA", "MID", "ZEBRA"]));
+      const ours = formatCfTypegenOutput(rawFixture(["ALPHA", "BRAVO", "MID", "ZEBRA"])); // adds BRAVO
+      const theirs = formatCfTypegenOutput(rawFixture(["ALPHA", "MID", "YANKEE", "ZEBRA"])); // adds YANKEE
+      const basePath = join(dir, "base.d.ts");
+      const oursPath = join(dir, "ours.d.ts");
+      const theirsPath = join(dir, "theirs.d.ts");
+      writeFileSync(basePath, base);
+      writeFileSync(oursPath, ours);
+      writeFileSync(theirsPath, theirs);
+
+      const merged = execFileSync("git", ["merge-file", "-p", oursPath, basePath, theirsPath], { encoding: "utf8" });
+      expect(merged).not.toContain("<<<<<<<");
+      expect(merged).toContain('| "BRAVO"');
+      expect(merged).toContain('| "YANKEE"');
+    } finally {
+      rmSync(dir, { recursive: true, force: true });
+    }
+  });
+
+  it("BASELINE: the SAME two additions DO conflict on the original unformatted single-line union", () => {
+    const dir = mkdtempSync(join(tmpdir(), "cf-typegen-merge-baseline-"));
+    try {
+      const base = rawFixture(["ALPHA", "MID", "ZEBRA"]);
+      const ours = rawFixture(["ALPHA", "BRAVO", "MID", "ZEBRA"]);
+      const theirs = rawFixture(["ALPHA", "MID", "YANKEE", "ZEBRA"]);
+      const basePath = join(dir, "base.d.ts");
+      const oursPath = join(dir, "ours.d.ts");
+      const theirsPath = join(dir, "theirs.d.ts");
+      writeFileSync(basePath, base);
+      writeFileSync(oursPath, ours);
+      writeFileSync(theirsPath, theirs);
+
+      let conflicted = false;
+      let merged = "";
+      try {
+        merged = execFileSync("git", ["merge-file", "-p", oursPath, basePath, theirsPath], { encoding: "utf8" });
+      } catch (error) {
+        conflicted = true;
+        merged = String((error as { stdout?: string }).stdout ?? "");
+      }
+      expect(conflicted).toBe(true);
+      expect(merged).toContain("<<<<<<<");
+    } finally {
+      rmSync(dir, { recursive: true, force: true });
+    }
+  });
+});

worker-configuration.d.ts

@@ -56,7 +56,46 @@ type StringifyValues<EnvType extends Record<string, unknown>> = {
 	[Binding in keyof EnvType]: EnvType[Binding] extends string ? EnvType[Binding] : string;
 };
 declare namespace NodeJS {
-	interface ProcessEnv extends StringifyValues<Pick<Cloudflare.Env, "GITHUB_APP_ID" | "GITHUB_APP_SLUG" | "GITHUB_OAUTH_CLIENT_ID" | "GITHUB_WEBHOOK_MAX_BODY_BYTES" | "GITTENSOR_UPSTREAM_REPO" | "GITTENSOR_UPSTREAM_REF" | "GITTENSOR_REGISTRY_URL" | "SCORING_TIME_DECAY_ENABLED" | "GITTENSORY_AUTO_FILE_DRIFT_ISSUES" | "GITTENSORY_DRIFT_ISSUE_REPO" | "PUBLIC_API_ORIGIN" | "PUBLIC_SITE_ORIGIN" | "ADMIN_GITHUB_LOGINS" | "GITTENSORY_REVIEW_UNIFIED_COMMENT" | "GITTENSORY_REVIEW_INLINE_COMMENTS" | "GITTENSORY_REVIEW_TEST_GENERATION" | "GITTENSORY_REVIEW_SAFETY" | "GITTENSORY_REVIEW_SCREENSHOTS" | "GITTENSORY_REVIEW_GROUNDING" | "GITTENSORY_REVIEW_REPUTATION" | "GITTENSORY_REVIEW_OPS" | "GITTENSORY_SWEEP_WATCHDOG" | "GITTENSORY_PR_RECONCILIATION" | "GITTENSORY_REVIEW_RAG" | "GITTENSORY_REVIEW_IMPACT_MAP" | "GITTENSORY_REVIEW_CULTURE_PROFILE" | "GITTENSORY_REVIEW_MEMORY" | "GITTENSORY_REVIEW_CONTENT_LANE" | "GITTENSORY_REVIEW_SELFTUNE" | "GITHUB_STATUS_ROLLUP_GRAPHQL" | "GITTENSORY_REVIEW_PLANNER" | "GITTENSORY_REVIEW_DRAFT" | "GITTENSORY_REVIEW_PARITY_AUDIT" | "GITTENSORY_REVIEW_REPOS" | "GITTENSORY_PUBLIC_STATS" | "GITTENSORY_PUBLIC_STATS_REPOS" | "GITTENSORY_DUPLICATE_WINNER" | "GITTENSORY_OPEN_PR_FILE_COLLISION">> {}
+	interface ProcessEnv extends StringifyValues<Pick<Cloudflare.Env,
+		| "ADMIN_GITHUB_LOGINS"
+		| "GITHUB_APP_ID"
+		| "GITHUB_APP_SLUG"
+		| "GITHUB_OAUTH_CLIENT_ID"
+		| "GITHUB_STATUS_ROLLUP_GRAPHQL"
+		| "GITHUB_WEBHOOK_MAX_BODY_BYTES"
+		| "GITTENSOR_REGISTRY_URL"
+		| "GITTENSOR_UPSTREAM_REF"
+		| "GITTENSOR_UPSTREAM_REPO"
+		| "GITTENSORY_AUTO_FILE_DRIFT_ISSUES"
+		| "GITTENSORY_DRIFT_ISSUE_REPO"
+		| "GITTENSORY_DUPLICATE_WINNER"
+		| "GITTENSORY_OPEN_PR_FILE_COLLISION"
+		| "GITTENSORY_PR_RECONCILIATION"
+		| "GITTENSORY_PUBLIC_STATS"
+		| "GITTENSORY_PUBLIC_STATS_REPOS"
+		| "GITTENSORY_REVIEW_CONTENT_LANE"
+		| "GITTENSORY_REVIEW_CULTURE_PROFILE"
+		| "GITTENSORY_REVIEW_DRAFT"
+		| "GITTENSORY_REVIEW_GROUNDING"
+		| "GITTENSORY_REVIEW_IMPACT_MAP"
+		| "GITTENSORY_REVIEW_INLINE_COMMENTS"
+		| "GITTENSORY_REVIEW_MEMORY"
+		| "GITTENSORY_REVIEW_OPS"
+		| "GITTENSORY_REVIEW_PARITY_AUDIT"
+		| "GITTENSORY_REVIEW_PLANNER"
+		| "GITTENSORY_REVIEW_RAG"
+		| "GITTENSORY_REVIEW_REPOS"
+		| "GITTENSORY_REVIEW_REPUTATION"
+		| "GITTENSORY_REVIEW_SAFETY"
+		| "GITTENSORY_REVIEW_SCREENSHOTS"
+		| "GITTENSORY_REVIEW_SELFTUNE"
+		| "GITTENSORY_REVIEW_TEST_GENERATION"
+		| "GITTENSORY_REVIEW_UNIFIED_COMMENT"
+		| "GITTENSORY_SWEEP_WATCHDOG"
+		| "PUBLIC_API_ORIGIN"
+		| "PUBLIC_SITE_ORIGIN"
+		| "SCORING_TIME_DECAY_ENABLED"
+	>> {}
 }
 
 // Begin runtime types