fix(code-mode): drive agents from local install, drop bundled engines

Skip the platform-native engine packages (~230 MB each) when staging the ACP adapters and point each adapter at the user's local claude/codex via CLAUDE_CODE_EXECUTABLE / CODEX_PATH, erroring clearly when neither is installed. The codex resolver mirrors claude's login-shell probe so nvm/fnm installs resolve on macOS/Linux. Shrinks each installer ~460 MB.

apps/x/apps/main/forge.config.cjs

@@ -16,11 +16,17 @@ const pkg = require('./package.json');
 //
 // Why we reconstruct a nested tree instead of copying node_modules: pnpm's store is a
 // symlink farm that legitimately holds multiple versions of the same package (e.g.
-// @agentclientprotocol/sdk 0.21 for claude vs 0.22 for codex, and the @openai/codex
-// launcher-vs-platform-binary alias). We rebuild an npm-style nested node_modules —
-// dereferencing symlinks and nesting on version conflict — which resolves correctly
-// regardless of pnpm layout. Platform-specific optional deps that aren't installed
-// for the current OS resolve to null and are skipped, so each OS ships its own binary.
+// @agentclientprotocol/sdk 0.21 for claude vs 0.22 for codex). We rebuild an npm-style
+// nested node_modules — dereferencing symlinks and nesting on version conflict — which
+// resolves correctly regardless of pnpm layout.
+//
+// What we DON'T bundle: the agents' native engines (claude.exe / codex.exe, ~230 MB
+// each, shipped as platform-specific packages). Code mode drives each agent from the
+// user's LOCAL install via CLAUDE_CODE_EXECUTABLE / CODEX_PATH (see
+// packages/core/src/code-mode/acp/agents.ts), so the bundled engines would be dead
+// weight. Skipping them keeps each OS installer ~470 MB smaller. (The adapters only
+// fall back to a bundled engine when those env vars are unset, which agents.ts never
+// leaves unset — it errors clearly if the local agent isn't installed.)
 function stageAcpAdapters(mainDir, destNodeModules) {
     const fs = require('fs');
     const ADAPTERS = [
@@ -28,6 +34,12 @@ function stageAcpAdapters(mainDir, destNodeModules) {
         '@agentclientprotocol/codex-acp',
     ];
 
+    // The bundled native engines, shipped as platform packages. Driven from the user's
+    // local install instead (see comment above), so they're excluded from staging.
+    const isNativeEngine = (key) =>
+        /^@anthropic-ai\/claude-agent-sdk-(win32|darwin|linux)/.test(key) || // bundled claude.exe
+        /^@openai\/codex-(win32|darwin|linux)/.test(key);                    // bundled codex.exe
+
     // Resolve a dependency's real directory by walking node_modules the way Node does,
     // looking for the package DIRECTORY. We deliberately do NOT use
     // require.resolve(`${key}/package.json`): that throws for packages whose `exports`
@@ -46,6 +58,7 @@ function stageAcpAdapters(mainDir, destNodeModules) {
     };
 
     let copied = 0;
+    const skippedEngines = new Set();
     const install = (srcDir, key, destNM, chain) => {
         const destDir = path.join(destNM, ...key.split('/'));
         if (fs.existsSync(destDir)) return; // already placed at this exact location
@@ -61,6 +74,7 @@ function stageAcpAdapters(mainDir, destNodeModules) {
         const deps = { ...pj.dependencies, ...pj.optionalDependencies };
         const nextChain = new Set(chain).add(srcDir);
         for (const depKey of Object.keys(deps)) {
+            if (isNativeEngine(depKey)) { skippedEngines.add(depKey); continue; }
             const depDir = realDirOf(depKey, srcDir);
             if (depDir) install(depDir, depKey, path.join(destDir, 'node_modules'), nextChain);
         }
@@ -73,6 +87,9 @@ function stageAcpAdapters(mainDir, destNodeModules) {
         }
         install(srcDir, key, destNodeModules, new Set());
     }
+    if (skippedEngines.size) {
+        console.log(`  (skipped bundled native engines — driven from local install: ${[...skippedEngines].join(', ')})`);
+    }
     return copied;
 }
 

apps/x/packages/core/src/code-mode/acp/agents.ts

@@ -3,6 +3,7 @@ import * as path from 'path';
 import { fileURLToPath } from 'url';
 import type { CodingAgent } from './types.js';
 import { resolveClaudeExecutable } from './claude-exec.js';
+import { resolveCodexExecutable } from './codex-exec.js';
 
 const require = createRequire(import.meta.url);
 
@@ -63,14 +64,36 @@ export function getAgentLaunchSpec(agent: CodingAgent): AgentLaunchSpec {
     const entry = resolveAdapterEntry(ADAPTER_PACKAGE[agent]);
     const env: NodeJS.ProcessEnv = { ...process.env };
 
-    // Point the Claude adapter at the real claude executable. On Windows this is
-    // mandatory (Node can't spawn the .cmd shim — EINVAL); on macOS/Linux it's a
-    // PATH safety net for GUI launches. Resolver is a no-op when claude isn't found,
-    // leaving the adapter to do its own lookup. (Codex relies on PATH for now — wire
-    // an equivalent when we add Codex support.)
+    // Point each adapter at the user's LOCAL agent executable. We intentionally do not
+    // bundle the agents' native engines (~230 MB each) into packaged builds — the
+    // adapters fall back to a bundled engine only when these are unset, and we strip
+    // those binaries during packaging (see apps/main/forge.config.cjs). So a local
+    // install is required; throw a clear error instead of letting the adapter fail
+    // cryptically on the absent bundled engine.
     if (agent === 'claude' && !env.CLAUDE_CODE_EXECUTABLE) {
+        // On Windows resolving the real .exe is also mandatory: Node can't spawn the
+        // .cmd shim (EINVAL). On macOS/Linux it doubles as a PATH safety net for GUI
+        // launches that don't inherit the login shell's PATH.
         const exe = resolveClaudeExecutable();
-        if (exe) env.CLAUDE_CODE_EXECUTABLE = exe;
+        if (!exe) {
+            throw new Error(
+                'Claude Code CLI not found. Install it (`npm i -g @anthropic-ai/claude-code`) to use Claude in code mode.',
+            );
+        }
+        env.CLAUDE_CODE_EXECUTABLE = exe;
+    }
+
+    if (agent === 'codex' && !env.CODEX_PATH) {
+        // codex-acp spawns this with shell:true on Windows (a .cmd shim is fine) and
+        // via PATH on unix. Without CODEX_PATH the adapter tries its bundled engine,
+        // which we don't ship — so resolve the local install or fail clearly.
+        const exe = resolveCodexExecutable();
+        if (!exe) {
+            throw new Error(
+                'Codex CLI not found. Install it (`npm i -g @openai/codex`) to use Codex in code mode.',
+            );
+        }
+        env.CODEX_PATH = exe;
     }
 
     // We spawn the adapter with process.execPath. Inside Electron's main process

apps/x/packages/core/src/code-mode/acp/codex-exec.ts

@@ -0,0 +1,65 @@
+import { execSync } from 'child_process';
+import * as path from 'path';
+import { existsSync } from 'fs';
+import { commonInstallPaths } from '../status.js';
+
+let cached: string | undefined;
+
+// Resolve the user's local `codex` launcher to hand the codex-acp adapter via
+// CODEX_PATH. We deliberately do NOT bundle Codex's ~230 MB native engine — the
+// adapter only falls back to a bundled `@openai/codex` when CODEX_PATH is unset, so
+// pointing it at the local install keeps packaged builds small.
+//
+// Unlike claude (which the adapter spawns directly, hitting the Windows .cmd EINVAL
+// trap), codex-acp spawns this with `shell: true` on Windows and via PATH on unix — so
+// a `.cmd` shim is fine and we don't need to dig out a raw `.exe`. We still resolve an
+// explicit path because Electron's runtime PATH can omit npm/pnpm global bin dirs even
+// when the user's shell has them. Returns undefined if codex can't be found — callers
+// then surface a clear "Codex CLI not found" error.
+export function resolveCodexExecutable(): string | undefined {
+    if (cached) return cached;
+    const resolved = process.platform === 'win32' ? resolveCodexOnWindows() : resolveCodexOnUnix();
+    if (resolved) cached = resolved;
+    return resolved;
+}
+
+// Windows: scan PATH (for codex.cmd/.exe) plus well-known npm/pnpm global bin dirs that
+// Electron's runtime PATH can omit. No login-shell trick here; codex-acp spawns with
+// shell:true so a `.cmd` shim is fine.
+function resolveCodexOnWindows(): string | undefined {
+    const exts = ['.cmd', '.exe', ''];
+    const pathDirs = (process.env.PATH ?? '')
+        .split(path.delimiter)
+        .map((d) => d.trim())
+        .filter(Boolean);
+    const fromPath = pathDirs.flatMap((dir) => exts.map((ext) => path.join(dir, `codex${ext}`)));
+    for (const candidate of [...fromPath, ...commonInstallPaths('codex')]) {
+        if (existsSync(candidate)) return candidate;
+    }
+    return undefined;
+}
+
+// macOS/Linux: GUI-launched Electron apps (Dock/Finder) often don't inherit the login
+// shell's PATH, so a node-version-manager install (nvm/fnm/asdf) won't be on
+// process.env.PATH. Ask a login shell first — it sees the user's full PATH — then fall
+// back to scanning the runtime PATH and well-known install dirs. Mirrors
+// resolveClaudeBinaryUnix in claude-exec.ts.
+function resolveCodexOnUnix(): string | undefined {
+    // Primary: a login shell sees the user's full PATH (~/.zprofile, nvm, homebrew, …).
+    try {
+        const out = execSync("/bin/sh -lc 'command -v codex'", { timeout: 5000, encoding: 'utf-8' }).trim();
+        if (out && existsSync(out)) return out;
+    } catch {
+        // not found on the login-shell PATH
+    }
+    // Fallback: scan the runtime PATH and well-known install locations directly.
+    const pathDirs = (process.env.PATH ?? '')
+        .split(path.delimiter)
+        .map((d) => d.trim())
+        .filter(Boolean);
+    const fromPath = pathDirs.map((dir) => path.join(dir, 'codex'));
+    for (const candidate of [...fromPath, ...commonInstallPaths('codex')]) {
+        if (existsSync(candidate)) return candidate;
+    }
+    return undefined;
+}