Fix piped workflow JSON output truncation

packages/cli/package.json

@@ -8,7 +8,7 @@
   },
   "scripts": {
     "cli": "bun src/cli.ts",
-    "test": "bun test src/commands/version.test.ts src/commands/setup.test.ts src/commands/skill.test.ts src/commands/doctor.test.ts src/commands/telemetry.test.ts && bun test src/commands/workflow.test.ts && bun test src/commands/isolation.test.ts && bun test src/commands/chat.test.ts && bun test src/commands/serve.test.ts && bun test src/commands/ai.test.ts",
+    "test": "bun test src/commands/version.test.ts src/commands/setup.test.ts src/commands/skill.test.ts src/commands/doctor.test.ts src/commands/telemetry.test.ts && bun test src/commands/workflow.test.ts && bun test src/commands/isolation.test.ts && bun test src/commands/chat.test.ts && bun test src/commands/serve.test.ts && bun test src/commands/ai.test.ts && bun test src/cli.test.ts src/utils/stdout.test.ts",
     "type-check": "bun x tsc --noEmit"
   },
   "dependencies": {

packages/cli/src/cli.test.ts

@@ -7,6 +7,7 @@
 import { describe, it, expect } from 'bun:test';
 import { parseArgs } from 'util';
 import * as git from '@archon/git';
+import { tmpdir } from 'node:os';
 
 // Test the argument parsing logic used in cli.ts
 describe('CLI argument parsing', () => {
@@ -398,9 +399,11 @@ describe('CLI git repo check', () => {
     });
 
     it('should return null for system directories outside any git repo', async () => {
-      // /tmp is typically not inside a git repo
-      // Note: This test may need adjustment if /tmp happens to be inside a repo
-      const result = await git.findRepoRoot('/tmp');
+      // The OS temp dir is not inside a git repo on any supported platform.
+      // Hardcoding '/tmp' fails on Windows, where that path does not exist —
+      // this file was absent from the package test script until #2384, so the
+      // POSIX assumption never surfaced in CI.
+      const result = await git.findRepoRoot(tmpdir());
       expect(result).toBeNull();
     });
   });
@@ -412,7 +415,7 @@ describe('CLI git repo check', () => {
 
     it('should detect existing directories', () => {
       expect(existsSync(process.cwd())).toBe(true);
-      expect(existsSync('/tmp')).toBe(true);
+      expect(existsSync(tmpdir())).toBe(true);
     });
 
     it('should detect non-existent directories', () => {

packages/cli/src/cli.ts

@@ -1026,7 +1026,14 @@ async function main(): Promise<number> {
   }
 }
 
-// Run main and exit with the returned code
+// Exit explicitly so a lingering handle (DB pool, spawned child, timer) can
+// never leave the CLI hanging after its work is done.
+//
+// This is safe for piped output because every machine-readable payload is
+// emitted through `writeStdout()`/`writeJsonLine()` (src/utils/stdout.ts), which
+// resolves only once the bytes have reached the OS. The #2384 truncation
+// happened inside `console.log` at call time — not at exit — so deferring the
+// exit would not have recovered it.
 main()
   .then(exitCode => {
     process.exit(exitCode);

packages/cli/src/commands/ai.test.ts

@@ -135,10 +135,21 @@ import {
 
 let logSpy: ReturnType<typeof spyOn<Console, 'log'>>;
 let errSpy: ReturnType<typeof spyOn<Console, 'error'>>;
+let stdoutSpy: ReturnType<typeof spyOn>;
 function out(): string {
   return [...logSpy.mock.calls, ...errSpy.mock.calls].flat().join('\n');
 }
 
+/**
+ * `--json` payloads go through `writeJsonLine()` (src/utils/stdout.ts), i.e.
+ * `process.stdout.write`, so a piped consumer can never get a truncated
+ * document (#2384). Capture them here; real-pipe delivery is covered by
+ * src/utils/stdout.test.ts.
+ */
+function jsonOut(): string {
+  return ((stdoutSpy.mock.calls[0]?.[0] as string) ?? '').trimEnd();
+}
+
 beforeEach(() => {
   enabled = true;
   mockPersist.mockClear();
@@ -154,10 +165,16 @@ beforeEach(() => {
   loadConfigResult = { assistant: 'claude', tiers: {} };
   logSpy = spyOn(console, 'log').mockImplementation(() => {});
   errSpy = spyOn(console, 'error').mockImplementation(() => {});
+  stdoutSpy = spyOn(process.stdout, 'write').mockImplementation((...args: unknown[]) => {
+    const callback = args.find(arg => typeof arg === 'function');
+    if (typeof callback === 'function') (callback as () => void)();
+    return true;
+  });
 });
 afterEach(() => {
   logSpy.mockRestore();
   errSpy.mockRestore();
+  stdoutSpy.mockRestore();
 });
 
 describe('gate (vault unavailable — defensive guard)', () => {
@@ -367,7 +384,7 @@ describe('aiTierListCommand', () => {
   it('--json emits structured output', async () => {
     loadConfigResult = { assistant: 'claude', tiers: {} };
     expect(await aiTierListCommand(true)).toBe(0);
-    const parsed = JSON.parse(logSpy.mock.calls[0]?.[0] as string) as {
+    const parsed = JSON.parse(jsonOut()) as {
       defaultAssistant: string;
       tiers: unknown[];
     };
@@ -523,7 +540,7 @@ describe('aiAliasListCommand', () => {
       aliases: { '@fast': { provider: 'claude', model: 'haiku' } },
     };
     expect(await aiAliasListCommand(true)).toBe(0);
-    const parsed = JSON.parse(logSpy.mock.calls[0]?.[0] as string) as { aliases: unknown[] };
+    const parsed = JSON.parse(jsonOut()) as { aliases: unknown[] };
     expect(Array.isArray(parsed.aliases)).toBe(true);
     expect(parsed.aliases.length).toBe(1);
   });

packages/cli/src/commands/ai.ts

@@ -27,6 +27,7 @@
  * identity so a connected key attaches to the same user across invocations.
  */
 import { password, text, isCancel, cancel } from '@clack/prompts';
+import { writeJsonLine } from '../utils/stdout';
 import { createLogger } from '@archon/paths';
 import {
   isPerUserProviderKeysEnabled,
@@ -481,17 +482,11 @@ export async function aiTierListCommand(json?: boolean): Promise<number> {
     });
 
     if (json) {
-      console.log(
-        JSON.stringify(
-          {
-            defaultAssistant: config.assistant,
-            userDefaultAssistant: userPrefs.defaultProvider ?? null,
-            tiers: rows,
-          },
-          null,
-          2
-        )
-      );
+      await writeJsonLine({
+        defaultAssistant: config.assistant,
+        userDefaultAssistant: userPrefs.defaultProvider ?? null,
+        tiers: rows,
+      });
       return 0;
     }
 
@@ -622,7 +617,7 @@ export async function aiAliasListCommand(json?: boolean): Promise<number> {
     }));
 
     if (json) {
-      console.log(JSON.stringify({ aliases: rows }, null, 2));
+      await writeJsonLine({ aliases: rows });
       return 0;
     }
 

packages/cli/src/commands/validate.ts

@@ -5,6 +5,7 @@
  */
 
 import { discoverWorkflowsWithConfig } from '@archon/workflows/workflow-discovery';
+import { writeStdout } from '../utils/stdout';
 import {
   validateWorkflowResources,
   validateCommand,
@@ -133,12 +134,12 @@ export async function validateWorkflowsCommand(
       const allNames = results.map(r => r.workflowName);
       const similar = findSimilar(name, allNames);
       if (json) {
-        console.log(
-          JSON.stringify({
+        await writeStdout(
+          `${JSON.stringify({
             error: `Workflow '${name}' not found`,
             suggestions: similar,
             available: allNames,
-          })
+          })}\n`
         );
       } else {
         console.error(`Workflow '${name}' not found.`);
@@ -166,16 +167,16 @@ export async function validateWorkflowsCommand(
   ).length;
 
   if (json) {
-    console.log(
-      JSON.stringify({
+    await writeStdout(
+      `${JSON.stringify({
         results: filteredResults,
         summary: {
           total: filteredResults.length,
           valid: filteredResults.length - totalErrors,
           errors: totalErrors,
           warnings: totalWarnings,
         },
-      })
+      })}\n`
     );
   } else {
     console.log(`\nValidating workflows in ${cwd}\n`);
@@ -215,7 +216,7 @@ export async function validateCommandsCommand(
     const result = await validateCommand(name, cwd, config);
 
     if (jsonOutput) {
-      console.log(JSON.stringify(result));
+      await writeStdout(`${JSON.stringify(result)}\n`);
     } else {
       const statusLabel = result.valid ? 'ok' : 'ERRORS';
       console.log(`\n  ${result.commandName.padEnd(40, ' ')} ${statusLabel}`);
@@ -242,16 +243,16 @@ export async function validateCommandsCommand(
   const totalErrors = totalCommandErrors + totalScriptErrors;
 
   if (jsonOutput) {
-    console.log(
-      JSON.stringify({
+    await writeStdout(
+      `${JSON.stringify({
         results: commandResults,
         scripts: scriptResults,
         summary: {
           total: commandResults.length + scriptResults.length,
           valid: commandResults.length + scriptResults.length - totalErrors,
           errors: totalErrors,
         },
-      })
+      })}\n`
     );
   } else {
     if (commandResults.length === 0 && scriptResults.length === 0) {