fix(e2e): bound secret configure pty output

scripts/e2e/secret-provider-integrations.mjs

@@ -149,6 +149,12 @@ function createOutputCapture(label, options = {}) {
     text() {
       return output;
     },
+    reset() {
+      output = "";
+      bytes = 0;
+      truncated = false;
+      scanTail = "";
+    },
     leakedForbiddenValue() {
       return leakedForbiddenValue;
     },
@@ -1606,7 +1612,7 @@ async function runPtySecretsConfigurePreset(envCtx) {
     cwd: command.options.cwd ?? process.cwd(),
     env: command.options.env ?? envCtx.env,
   });
-  let output = "";
+  const output = createOutputCapture("secrets configure stdout");
   let phase = "providers-menu";
   const sendKeys = (keys) => {
     keys.forEach((key, index) => {
@@ -1616,22 +1622,23 @@ async function runPtySecretsConfigurePreset(envCtx) {
   return await new Promise((resolve, reject) => {
     const timer = setTimeout(() => {
       child.kill();
-      reject(new Error(`secrets configure preset timed out: ${scrub(output)}`));
+      reject(new Error(`secrets configure preset timed out: ${scrub(output.text())}`));
     }, 60000);
     child.onData((data) => {
-      output += data;
-      if (phase === "providers-menu" && output.includes("Configure secret providers")) {
+      output.append(data);
+      const outputText = output.text();
+      if (phase === "providers-menu" && outputText.includes("Configure secret providers")) {
         phase = "selecting-preset";
         sendKeys(["\x1b[B", "\r"]);
         return;
       }
-      if (phase === "selecting-preset" && output.includes("Select plugin preset")) {
+      if (phase === "selecting-preset" && outputText.includes("Select plugin preset")) {
         phase = "preset-selected";
         sendKeys(["\r"]);
-        output = "";
+        output.reset();
         return;
       }
-      if (phase === "preset-selected" && output.includes("Configure secret providers")) {
+      if (phase === "preset-selected" && outputText.includes("Configure secret providers")) {
         phase = "continue-selected";
         sendKeys(["\x1b[A", "\r"]);
       }
@@ -1639,10 +1646,10 @@ async function runPtySecretsConfigurePreset(envCtx) {
     child.onExit(({ exitCode }) => {
       clearTimeout(timer);
       if (exitCode !== 0) {
-        reject(new Error(`secrets configure preset failed (${exitCode}): ${scrub(output)}`));
+        reject(new Error(`secrets configure preset failed (${exitCode}): ${scrub(output.text())}`));
         return;
       }
-      resolve(output);
+      resolve(output.text());
     });
   });
 }
@@ -1858,6 +1865,7 @@ export {
   cleanupEnv,
   expectGatewayStartupFails,
   gatewayCall,
+  runPtySecretsConfigurePreset,
   runCommand,
   startGateway,
   waitForManagedGatewayStatus,

test/scripts/secret-provider-integrations.test.ts

@@ -114,6 +114,25 @@ function writeSignaledStartupOpenClaw(root: string): string {
   return scriptPath;
 }
 
+function writeNoisySecretsConfigureOpenClaw(root: string): string {
+  const scriptPath = path.join(root, "fake-noisy-secrets-configure-openclaw.mjs");
+  fs.writeFileSync(
+    scriptPath,
+    [
+      "#!/usr/bin/env node",
+      "const args = process.argv.slice(2);",
+      "if (args[0] === 'secrets' && args[1] === 'configure') {",
+      "  process.stdout.write('x'.repeat(4096));",
+      "  process.exit(7);",
+      "}",
+      "process.exit(2);",
+      "",
+    ].join("\n"),
+    { mode: 0o755 },
+  );
+  return scriptPath;
+}
+
 function runProofHarness(
   root: string,
   fakeOpenClaw: string,
@@ -237,6 +256,47 @@ describe("secret provider integration proof harness", () => {
     }
   });
 
+  it.runIf(process.platform !== "win32")("bounds captured PTY configure output", async () => {
+    const root = makeTempDir();
+    const fakeOpenClaw = writeNoisySecretsConfigureOpenClaw(root);
+    const previousLimit = process.env.OPENCLAW_SECRET_PROOF_OUTPUT_BYTES;
+    const previousEntry = process.env.OPENCLAW_ENTRY;
+    process.env.OPENCLAW_SECRET_PROOF_OUTPUT_BYTES = "128";
+    process.env.OPENCLAW_ENTRY = fakeOpenClaw;
+    try {
+      const proof = await import(
+        `${pathToFileURL(proofScriptPath).href}?case=pty-output-${Date.now()}`
+      );
+
+      const error = await proof
+        .runPtySecretsConfigurePreset({
+          env: {
+            ...process.env,
+            OPENCLAW_ENTRY: fakeOpenClaw,
+          },
+        })
+        .catch((caught: unknown) => caught);
+
+      expect(error).toBeInstanceOf(Error);
+      expect((error as Error).message).toContain("secrets configure preset failed (7)");
+      expect((error as Error).message).toContain(
+        "secrets configure stdout truncated after 128 bytes",
+      );
+      expect((error as Error).message.length).toBeLessThan(600);
+    } finally {
+      if (previousLimit === undefined) {
+        delete process.env.OPENCLAW_SECRET_PROOF_OUTPUT_BYTES;
+      } else {
+        process.env.OPENCLAW_SECRET_PROOF_OUTPUT_BYTES = previousLimit;
+      }
+      if (previousEntry === undefined) {
+        delete process.env.OPENCLAW_ENTRY;
+      } else {
+        process.env.OPENCLAW_ENTRY = previousEntry;
+      }
+    }
+  });
+
   it.runIf(process.platform !== "win32")(
     "fails mandatory commands that exit by signal",
     async () => {