fix(theseus/updater): run the installer only after the app has exited, via a detached batch helper with self-heal

A 0.3.44 → 0.3.45 auto-update on 2026-09-11 left the install without
app.asar and ffmpeg.dll ("ffmpeg.dll not found" at launch). The setup was
hash-verified; the old-version uninstaller had moved the whole old install
into its temp folder when both NSIS processes died ~8 s after the spawn,
and the install step never wrote a file. The killer was not identified, so
every overlap with the app's own lifetime is removed instead:

- install-update-now no longer spawns the setup; it records the path and
  quits. will-quit writes <userData>\update-helper.cmd and starts it as a
  detached cmd.exe (verified to outlive the app; not a child of ours).
- The helper waits for our PID to be gone (child powershell Wait-Process),
  gives Chromium's children a grace period, runs the setup directly, and
  runs it once more if resources\app.asar is missing afterwards — the
  installer is idempotent, so a second pass repairs a torn install. The
  helper deletes itself.
- Zone.Identifier is stripped from the verified download so nothing that
  starts it through the shell raises a mark-of-the-web prompt.

Console-less cmd.exe traps discovered and designed around (see the module):
child console programs' redirected stdout is empty (no tasklist|find
probing), `start /wait` on a .cmd hangs, a detached powershell.exe
started straight from Node does nothing, `timeout` needs a console.
Scenario tests: setup starts only after the process exits, once with
app.asar present, twice without, helper gone afterwards.

lib/update-helper.cjs

@@ -0,0 +1,67 @@
+// Builds the batch script that installs a downloaded Theseus update AFTER
+// the browser has exited. Pure function, no Electron — main.js writes the
+// result next to its user data and starts it detached from will-quit; the
+// tests run it against a dummy process and a fake setup.
+//
+// Why a helper at all: on 2026-09-11 an update ran while the app was still
+// shutting down. The NSIS installer's uninstall-old-version step had moved
+// the whole old install into its temp folder when both NSIS processes died
+// ~8 s in, and the install step never wrote a file — the user was left with
+// a folder missing app.asar and ffmpeg.dll. The exact killer was never
+// identified, so this removes every overlap with our own lifetime:
+//
+//   1. poll until our PID is gone (tasklist), then a grace period for
+//      Chromium's child processes to follow;
+//   2. start the installer from a process that is not in any job of ours
+//      (a detached cmd.exe survives the app exiting — verified — whereas a
+//      detached powershell.exe silently does nothing without a console, and
+//      a non-detached child is killed with the app);
+//   3. wait for the installer and, if resources\app.asar is missing from the
+//      install dir afterwards, run it once more — the installer is
+//      idempotent and a second pass repairs a torn install.
+//
+// Batch specifics: `timeout` refuses to run without a console, so sleeps are
+// `ping -n <n+1> 127.0.0.1`; the setup is launched with `start "" /wait`
+// so the script blocks until the installer exits. The script deletes itself.
+function buildUpdateHelperCmd({ pid, setupPath, installDir, args = ["/S", "--force-run"], graceSec = 2, maxWaitSec = 120 }) {
+  if (!Number.isInteger(pid) || pid <= 0) throw new Error("pid required");
+  if (typeof setupPath !== "string" || !setupPath || /["\r\n%]/.test(setupPath)) throw new Error("setupPath required (no quotes, percent signs or newlines)");
+  if (typeof installDir !== "string" || !installDir || /["\r\n%]/.test(installDir)) throw new Error("installDir required (no quotes, percent signs or newlines)");
+  const argStr = args.map(String).join(" ");
+  if (/["\r\n%]/.test(argStr)) throw new Error("installer args must not contain quotes, percent signs or newlines");
+  const grace = Math.max(0, graceSec | 0) + 1;
+  const maxIter = Math.max(1, maxWaitSec | 0);
+  // Everything runs inside a console-less cmd.exe, which has two traps
+  // (both hit while writing this): child console programs' redirected
+  // stdout comes back EMPTY (tasklist, wmic, even powershell — so no
+  // "tasklist | find" style probing), and `start /wait` is unreliable. What
+  // does work there: exit codes, timing, cmd-internal redirection, and a
+  // child powershell.exe blocking in Wait-Process. So the wait is a child
+  // PowerShell that returns once our PID is gone (or after maxWaitSec), the
+  // installer is invoked directly (from a batch file cmd.exe waits for it,
+  // and no ShellExecute means no mark-of-the-web prompt), and tools are
+  // addressed by full path so a Unix toolchain on PATH can't shadow them.
+  const S32 = "%SystemRoot%\\System32";
+  const PS = `${S32}\\WindowsPowerShell\\v1.0\\powershell.exe`;
+  return [
+    "@echo off",
+    "setlocal",
+    `set "SETUP=${setupPath}"`,
+    `set "ASAR=${installDir}\\resources\\app.asar"`,
+    `"${PS}" -NoProfile -NonInteractive -Command "Wait-Process -Id ${pid} -Timeout ${maxIter} -ErrorAction SilentlyContinue"`,
+    `"${S32}\\ping.exe" -n ${grace} 127.0.0.1 >nul`,
+    `"%SETUP%" ${argStr}`,
+    `if not exist "%ASAR%" (`,
+    `  "${S32}\\ping.exe" -n 4 127.0.0.1 >nul`,
+    `  "%SETUP%" ${argStr}`,
+    ")",
+    "endlocal",
+    // Self-delete without cmd.exe's "The batch file cannot be found" when it
+    // tries to read the next line: the (goto) 2>nul idiom ends the batch
+    // context first, then del runs on the same line.
+    `(goto) 2>nul & del "%~f0"`,
+    "",
+  ].join("\r\n");
+}
+
+module.exports = { buildUpdateHelperCmd };

main.js

@@ -2341,6 +2341,11 @@ function installDownloadTracker() {
           }
           updateDownloadPath = savedPath;
           updateDownloadState = "ready";
+          // Drop the mark-of-the-web Chromium stamps on downloads. Our
+          // hash check above is the trust decision; the zone marker only
+          // makes Windows raise a security prompt if the file is ever
+          // started through the shell.
+          try { fs.unlinkSync(savedPath + ":Zone.Identifier"); } catch {}
           console.log(`[update] silent fetch complete + verified: ${savedPath}`);
           emitUpdateAvailable();
         });
@@ -3628,16 +3633,37 @@ ipcMain.handle("recheck-update", async () => {
 // commit puts --force-run back on so the auto-restart is part of the
 // standard flow again. --updated stays out: the earlier E2E showed it
 // wasn't load-bearing correctness for our NSIS config.
+//
+// 2026-09-11: an update ran while the app was still shutting down, both NSIS
+// processes died ~8 s in, and the install was left without app.asar. The
+// installer is no longer spawned from here: install-update-now only records
+// the setup path and quits; will-quit then starts a detached batch helper
+// that waits for this PID to be gone, runs the installer, and re-runs it
+// once if app.asar is missing afterwards. See lib/update-helper.cjs for
+// the script, the console-less cmd.exe traps, and the reasoning.
+let pendingInstallerPath = null;
 ipcMain.handle("install-update-now", () => {
   if (updateDownloadState !== "ready" || !updateDownloadPath) return false;
-  try {
+  pendingInstallerPath = updateDownloadPath;
-    const p = spawn(updateDownloadPath, ["/S", "--force-run"], { detached: true, stdio: "ignore" });
+  app.quit();
-    p.unref();
-  } catch (e) { console.warn("update spawn failed:", e?.message); return false; }
-  // Give the child a moment to inherit our arguments before we exit.
-  setTimeout(() => app.quit(), 400);
   return true;
 });
+app.on("will-quit", () => {
+  if (!pendingInstallerPath) return;
+  const setupPath = pendingInstallerPath;
+  pendingInstallerPath = null;
+  try {
+    const { buildUpdateHelperCmd } = require("./lib/update-helper.cjs");
+    const cmdPath = path.join(app.getPath("userData"), "update-helper.cmd");
+    fs.writeFileSync(cmdPath, buildUpdateHelperCmd({ pid: process.pid, setupPath, installDir: path.dirname(process.execPath) }));
+    // A detached cmd.exe outlives this process (verified) and is in no job
+    // of ours; the batch file itself waits for our PID to disappear.
+    const helper = spawn("cmd.exe", [`/d /c "${cmdPath}"`],
+      { detached: true, stdio: "ignore", windowsHide: true, windowsVerbatimArguments: true });
+    helper.unref();
+    console.log(`[update] helper armed for ${setupPath}`);
+  } catch (e) { console.warn("[update] helper spawn failed:", e?.message); }
+});
 // Home page editable cards. Origin-gated to home.html — random pages that
 // snoop the preload can't act on the local file.
 ipcMain.handle("home-cards-get",   (e) => isHomePageSender(e.sender) ? loadHomeCards() : []);