From 6db98852c52c29b9737528854d57a0cc1b97f667 Mon Sep 17 00:00:00 2001
From: akmhatey-ai <260399619+akmhatey-ai@users.noreply.github.com>
Date: Sun, 17 May 2026 08:30:47 +0200
Subject: [PATCH] fix(npm): fail postinstall when binary download fails

Signed-off-by: akmhatey-ai <260399619+akmhatey-ai@users.noreply.github.com>
---
 .github/workflows/ci.yml |  1 +
 npm/postinstall.js       |  5 ++--
 npm/postinstall.test.js  | 58 ++++++++++++++++++++++++++++++++++++++++
 package.json             |  1 +
 4 files changed, 62 insertions(+), 3 deletions(-)
 create mode 100644 npm/postinstall.test.js

diff --git a/.github/workflows/ci.yml b/.github/workflows/ci.yml
index 16a12d7..1db9b1b 100644
--- a/.github/workflows/ci.yml
+++ b/.github/workflows/ci.yml
@@ -52,4 +52,5 @@ jobs:
         with:
           node-version: "20"
       - run: OPTIQOR_SKIP_POSTINSTALL=1 npm install --ignore-scripts
+      - run: npm run test:postinstall
       - run: npm pack
diff --git a/npm/postinstall.js b/npm/postinstall.js
index 07bf79b..b05b6dd 100644
--- a/npm/postinstall.js
+++ b/npm/postinstall.js
@@ -74,9 +74,8 @@ const pipelineP = promisify(pipeline);
     console.log('optiqor: ready. Run `optiqor --version` to verify.');
   } catch (err) {
     console.error('optiqor: failed to install binary:', err.message);
-    console.error('optiqor: this is non-fatal — build from source if needed:');
+    console.error('optiqor: build from source if needed:');
     console.error('  go install github.com/optiqor/optiqor-cli/cmd/optiqor@latest');
-    // Exit 0 so npm install does not abort entirely.
-    process.exit(0);
+    process.exit(1);
   }
 })();
diff --git a/npm/postinstall.test.js b/npm/postinstall.test.js
new file mode 100644
index 0000000..ae6f56b
--- /dev/null
+++ b/npm/postinstall.test.js
@@ -0,0 +1,58 @@
+#!/usr/bin/env node
+
+const assert = require('assert/strict');
+const fs = require('fs');
+const path = require('path');
+const { spawnSync } = require('child_process');
+
+const root = path.join(__dirname, '..');
+const vendorDir = path.join(root, 'vendor');
+
+const runPostinstallWithHttpFailure = () => {
+  const script = `
+    const https = require('https');
+    const { Readable } = require('stream');
+
+    https.get = (url, callback) => {
+      const response = new Readable({
+        read() {
+          this.push(null);
+        },
+      });
+      response.statusCode = 404;
+      response.headers = {};
+      process.nextTick(() => callback(response));
+
+      return {
+        on() {
+          return this;
+        },
+      };
+    };
+
+    Object.defineProperty(process, 'platform', { value: 'linux' });
+    Object.defineProperty(process, 'arch', { value: 'x64' });
+    require('./npm/postinstall.js');
+  `;
+
+  return spawnSync(process.execPath, ['-e', script], {
+    cwd: root,
+    encoding: 'utf8',
+  });
+};
+
+fs.rmSync(vendorDir, { recursive: true, force: true });
+
+try {
+  const result = runPostinstallWithHttpFailure();
+
+  assert.equal(
+    result.status,
+    1,
+    `expected failed binary download to exit 1\nstdout:\n${result.stdout}\nstderr:\n${result.stderr}`
+  );
+  assert.match(result.stderr, /failed to install binary: HTTP 404/);
+  assert.doesNotMatch(result.stderr, /non-fatal/);
+} finally {
+  fs.rmSync(vendorDir, { recursive: true, force: true });
+}
diff --git a/package.json b/package.json
index ecb38c2..c05aa31 100644
--- a/package.json
+++ b/package.json
@@ -26,6 +26,7 @@
   },
   "scripts": {
     "postinstall": "node ./npm/postinstall.js",
+    "test:postinstall": "node ./npm/postinstall.test.js",
     "test": "node -e \"require('./npm/index.js')\""
   },
   "files": [