From fe5371ac56913784e7f63f5e8006c9f4e6687a53 Mon Sep 17 00:00:00 2001
From: Adil Hafeez <adil.hafeez@gmail.com>
Date: Fri, 24 Apr 2026 16:53:43 -0700
Subject: [PATCH] ci: add zero-config smoke test for `planoai up` with no args

The existing native-smoke-test always passes a config file, so the
`synthesize_default_config` branch in `cli/planoai/main.py` is never
exercised in CI. That branch was the source of a recent UnboundLocalError
that only reproduced when invoking `planoai up` with no args in a
directory without a `plano.yaml` (fixed in #916).

Add a follow-up step in the same job that runs `planoai up` from an
empty temp directory, asserts `~/.plano/default_config.yaml` is written,
performs a healthz check, and shuts down. Reuses the binaries already
built earlier in the job to keep CI time flat.

Made-with: Cursor
---
 .github/workflows/ci.yml | 31 +++++++++++++++++++++++++++++++
 1 file changed, 31 insertions(+)

diff --git a/.github/workflows/ci.yml b/.github/workflows/ci.yml
index 0e8722ce..4d980ec8 100644
--- a/.github/workflows/ci.yml
+++ b/.github/workflows/ci.yml
@@ -107,6 +107,37 @@ jobs:
         if: always()
         run: planoai down || true
 
+      # ── Zero-config path: `planoai up` with no args, no plano.yaml in cwd.
+      # Exercises the synthesize_default_config branch in cli/planoai/main.py
+      # which is otherwise never hit by the smoke test above.
+      - name: Zero-config smoke test
+        env:
+          OPENAI_API_KEY: test-key-not-used
+        run: |
+          empty_dir="$(mktemp -d)"
+          cd "$empty_dir"
+          test ! -f plano.yaml
+          planoai up
+          test -f "$HOME/.plano/default_config.yaml"
+
+      - name: Zero-config health check
+        run: |
+          for i in $(seq 1 30); do
+            if curl -sf http://localhost:12000/healthz > /dev/null 2>&1; then
+              echo "Zero-config health check passed"
+              exit 0
+            fi
+            sleep 1
+          done
+          echo "Zero-config health check failed after 30s"
+          cat ~/.plano/run/logs/envoy.log || true
+          cat ~/.plano/run/logs/brightstaff.log || true
+          exit 1
+
+      - name: Stop plano (zero-config)
+        if: always()
+        run: planoai down || true
+
   # ──────────────────────────────────────────────
   # Single Docker build — shared by all downstream jobs
   # ──────────────────────────────────────────────