fix(01-10): vitest build-test it() timeout — bump to 30s for slower welcome-page build

The build-completes Tier-1 gate at tests/background/no-test-hooks-in-prod-bundle.test.ts:247
was racing vitest's default 5000ms it() ceiling. Plan 01-10 closure shipped the welcome
page (commits d48a715 welcome mark + 49f087f welcome HTML/CSS/JS + 8 WOFF2 fonts) which
slowed standalone `npm run build` from ~2.88s to ~5.28s. The exec-level
BUILD_TIMEOUT_MS = 60_000 child-process bound was correctly declared at line 240, but
the surrounding it() block had no timeout option, so the 5s default fired first and the
60s exec bound was never reachable.

Surgical fix: add `, 30_000` 3rd arg to the it() call. 30s is ~6× the observed build
duration and well below the 60s exec ceiling, so both bounds remain meaningfully
active. SKIP_BUILD=1 env-var escape hatch untouched.

Acceptance gates:
- `npm test` (FULL, no SKIP_BUILD=1): 150/150 GREEN, exit 0
- `npx tsc --noEmit`: exit 0
- `npm run build`: exit 0
- Tier-1 grep gate: PASS (all 12 FORBIDDEN_HOOK_STRINGS asserted against dist/)

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>

.planning/debug/resolved/01-10-vitest-build-test-timeout.md

@@ -0,0 +1,82 @@
+---
+slug: 01-10-vitest-build-test-timeout
+status: resolved
+goal: find_and_fix
+trigger: "npm test (full run, no SKIP_BUILD=1) fails 1/150 with timeout in tests/background/no-test-hooks-in-prod-bundle.test.ts at line 247 — Test timed out in 5000ms"
+phase: 01-stabilize-video-pipeline
+plan: 01-10
+opened: 2026-05-20
+closed: 2026-05-20
+orchestrator_diagnosed: true
+---
+
+# Debug session 01-10-vitest-build-test-timeout — vitest it() default 5s ceiling races slower welcome-page build
+
+## Problem statement
+
+After Plan 01-10 closure (commits d48a715 welcome mark + 4bba679 notif-text), `npm test` (full run, no `SKIP_BUILD=1`) failed 1/150 with a vitest timeout in `tests/background/no-test-hooks-in-prod-bundle.test.ts` at line 247:
+
+```
+FAIL  tests/background/no-test-hooks-in-prod-bundle.test.ts > production bundle has no test-hook leaks (Tier-1 gate — T-1-11-01) > npm run build completes and dist/ exists with at least one chunk
+Error: Test timed out in 5000ms.
+```
+
+Standalone `npm run build` had slowed from ~2.88s (pre-Plan-01-10) to ~5.28s due to welcome page Vite processing + SVG `?url` import + 8 WOFF2 fonts shipped in d48a715 / 49f087f. With the build now exceeding 5s, vitest's default 5000ms `it()` ceiling races and loses.
+
+`SKIP_BUILD=1 npm test` was passing 150/150 GREEN, confirming this was purely a test-infrastructure timeout-tuning issue, NOT a real build/grep-gate regression.
+
+## Root cause
+
+The `it()` block at `tests/background/no-test-hooks-in-prod-bundle.test.ts:247` was declared without a 3rd-arg timeout option:
+
+```ts
+it('npm run build completes and dist/ exists with at least one chunk', async () => {
+  if (process.env.SKIP_BUILD !== '1') {
+    await runProductionBuild();
+  }
+  // ...
+});  // <-- no timeout 3rd arg → vitest's 5000ms default applies
+```
+
+The test author had correctly bounded the EXEC-level child-process timeout via `BUILD_TIMEOUT_MS = 60_000` at line 240 (passed to `execFileAsync`), but **forgot to bound the surrounding `it()` block**. Vitest's default it() timeout is 5000ms; the build now takes ~5.28s, so the it() ceiling fires before the exec bound is even close.
+
+This is the classic "two-tier timeout where only one tier is configured" bug. The exec timeout existed but was useless because the outer it() timeout fired first.
+
+## Fix design
+
+Surgical one-line change: add `, 30_000` as the 3rd arg to the failing `it()` call.
+
+30 seconds was chosen because:
+- Generously above the observed 5.28s build + npm overhead (~6× headroom)
+- Well below the 60s exec bound (`BUILD_TIMEOUT_MS`), so the exec timeout remains the dominant ceiling for true hangs
+- Above the 15s minimum requested by the orchestrator
+- Consistent with vitest convention for build-touching it() blocks (real-IO tests routinely declare 10s+ ceilings)
+
+Inline comment added above the `it()` documenting why the 30s ceiling exists, citing the +2.4s welcome-page-asset slowdown and the relationship to `BUILD_TIMEOUT_MS`.
+
+The alternative — setting a global `testTimeout` in `vitest.config.ts` — was rejected because:
+- 95% of vitest cases are pure-CPU and should keep the 5s default (catches accidental hangs fast)
+- Only this one it() touches IO at build scale
+- Per-it() timeouts are the standard vitest idiom for "this specific test does slow IO"
+
+`SKIP_BUILD=1` env-var escape hatch left untouched for CI environments.
+
+## Files modified
+
+- `tests/background/no-test-hooks-in-prod-bundle.test.ts` (line 247 it() — added `, 30_000` 3rd arg + 7-line explanatory comment above)
+
+## Acceptance gates — all PASS
+
+- `npm test` (FULL run, no SKIP_BUILD=1): **150/150 GREEN**, exit 0, 12.89s total
+- `npx tsc --noEmit`: exit 0
+- `npm run build`: exit 0, 4.86s (within new 30s it() ceiling with ~6× margin)
+- Tier-1 grep gate: PASS (all 12 FORBIDDEN_HOOK_STRINGS asserted against `dist/`, including the build-completes gate that was previously timing out — now passes within the new ceiling)
+
+## Noteworthy
+
+- **The exec-level `BUILD_TIMEOUT_MS = 60_000` ceiling still bounds the child process.** This fix only adjusts the SURROUNDING vitest it() ceiling so the exec bound becomes reachable. If `npm run build` ever truly hangs, the exec timeout fires at 60s; the it() ceiling fires at 30s. Both bounds remain active and meaningful.
+- **No SKIP_BUILD logic touched.** CI environments using `SKIP_BUILD=1` (with a pre-existing dist/) skip the slow path entirely and are unaffected.
+- **Build slowdown attribution** (for future archaeology):
+  - d48a715: welcome page mokosh-mark.svg via `?url` import (+~0.4s Vite asset processing)
+  - 49f087f: welcome HTML/CSS/JS entries + 8 WOFF2 font assets (+~2.0s emit + manifest)
+  - Net: ~2.88s → ~5.28s on this hardware

tests/background/no-test-hooks-in-prod-bundle.test.ts

@@ -244,6 +244,13 @@ async function runProductionBuild(): Promise<void> {
 }
 
 describe('production bundle has no test-hook leaks (Tier-1 gate — T-1-11-01)', () => {
+  // Plan 01-10 closure: `npm run build` slowed from ~2.88s → ~5.28s after
+  // the welcome page assets landed (welcome HTML + SVG ?url import + 8 WOFF2
+  // fonts shipped in d48a715 / 49f087f). Vitest's default 5000ms it() ceiling
+  // now races the build child. The EXEC-level `BUILD_TIMEOUT_MS = 60_000`
+  // bound on the child process still applies; this it()-level 30000ms
+  // ceiling is the surrounding-block companion. 30s is generously above the
+  // observed 5.28s + npm overhead and well below the 60s exec bound.
   it('npm run build completes and dist/ exists with at least one chunk', async () => {
     if (process.env.SKIP_BUILD !== '1') {
       await runProductionBuild();
@@ -259,7 +266,7 @@ describe('production bundle has no test-hook leaks (Tier-1 gate — T-1-11-01)',
       `dist/ is empty after npm run build — the build produced no output, which is a different ` +
         `regression class than a hook leak. Investigate before proceeding to the hook-leak assertion.`,
     ).toBeGreaterThan(0);
-  });
+  }, 30_000);
 
   for (const needle of FORBIDDEN_HOOK_STRINGS) {
     it(`production bundle does not contain '${needle}' (T-1-11-01 surface)`, () => {