fix: explicitly rebuild better-sqlite3 for Electron ABI in afterPack

Root cause: electron-builder's @electron/rebuild only rebuilds native
modules found in the `files` config. Since better-sqlite3 enters the
app through extraResources (via .next/standalone/), it was skipped.
The afterPack hook was copying the system Node.js ABI (127) instead
of the required Electron ABI (143).

Fix:
- afterPack now explicitly calls `npx electron-rebuild` targeting the
  exact Electron version and architecture from the build context
- Falls back to @electron/rebuild programmatic API if CLI fails
- Fails the build if rebuild cannot complete (no silent failures)
- Adds file size logging for verification
- Excludes `release/` from extraResources to prevent recursive nesting
- Adds startup ABI compatibility check in Electron main process with
  friendly error dialog instead of cryptic crash

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

scripts/after-pack.js

@@ -1,39 +1,84 @@
 /**
  * electron-builder afterPack hook.
  *
- * After @electron/rebuild recompiles native modules for Electron's ABI,
- * copy the rebuilt better_sqlite3.node into the standalone resources
- * (which still has the system-Node version from `next build`).
+ * The standard @electron/rebuild step only rebuilds native modules found
+ * in the `files` config. Since better-sqlite3 enters the app through
+ * extraResources (via .next/standalone/), it gets skipped.
+ *
+ * This hook:
+ * 1. Explicitly rebuilds better-sqlite3 for the target Electron ABI
+ * 2. Copies the rebuilt .node into all locations within standalone resources
  */
 const fs = require('fs');
 const path = require('path');
+const { execSync } = require('child_process');
 
 module.exports = async function afterPack(context) {
   const appOutDir = context.appOutDir;
+  const arch = context.arch;
+  // electron-builder arch enum: 1=x64, 3=arm64, etc.
+  const archName = arch === 3 ? 'arm64' : arch === 1 ? 'x64' : arch === 0 ? 'ia32' : String(arch);
+  const platform = context.packager.platform.name; // 'mac', 'windows', 'linux'
 
-  // Source: the rebuilt .node file in the project's node_modules
+  // Get Electron version from packager config or from installed package
+  const electronVersion =
+    context.electronVersion ||
+    context.packager?.config?.electronVersion ||
+    require(path.join(process.cwd(), 'node_modules', 'electron', 'package.json')).version;
+
+  console.log(`[afterPack] Electron ${electronVersion}, arch=${archName}, platform=${platform}`);
+
+  // Step 1: Explicitly rebuild better-sqlite3 for the target Electron version
+  const projectDir = process.cwd();
+  console.log('[afterPack] Rebuilding better-sqlite3 for Electron ABI...');
+
+  try {
+    // Use @electron/rebuild via npx (it's a dependency of electron-builder)
+    const rebuildCmd = `npx electron-rebuild -f -o better-sqlite3 -v ${electronVersion} -a ${archName}`;
+    console.log(`[afterPack] Running: ${rebuildCmd}`);
+    execSync(rebuildCmd, {
+      cwd: projectDir,
+      stdio: 'inherit',
+      timeout: 120000,
+    });
+    console.log('[afterPack] Rebuild completed successfully');
+  } catch (err) {
+    console.error('[afterPack] Failed to rebuild better-sqlite3:', err.message);
+    // Try alternative: use @electron/rebuild programmatically
+    try {
+      const { rebuild } = require('@electron/rebuild');
+      await rebuild({
+        buildPath: projectDir,
+        electronVersion: electronVersion,
+        arch: archName,
+        onlyModules: ['better-sqlite3'],
+        force: true,
+      });
+      console.log('[afterPack] Rebuild via @electron/rebuild API succeeded');
+    } catch (err2) {
+      console.error('[afterPack] @electron/rebuild API also failed:', err2.message);
+      throw new Error('Cannot rebuild better-sqlite3 for Electron ABI');
+    }
+  }
+
+  // Step 2: Verify the rebuilt .node file
   const rebuiltSource = path.join(
-    process.cwd(),
-    'node_modules',
-    'better-sqlite3',
-    'build',
-    'Release',
-    'better_sqlite3.node'
+    projectDir, 'node_modules', 'better-sqlite3', 'build', 'Release', 'better_sqlite3.node'
   );
 
   if (!fs.existsSync(rebuiltSource)) {
-    console.warn('[afterPack] Rebuilt better_sqlite3.node not found at', rebuiltSource);
-    return;
+    throw new Error(`[afterPack] Rebuilt better_sqlite3.node not found at ${rebuiltSource}`);
   }
 
-  // Find all better_sqlite3.node files inside the standalone resources
+  const sourceStats = fs.statSync(rebuiltSource);
+  console.log(`[afterPack] Rebuilt .node file: ${rebuiltSource} (${sourceStats.size} bytes, mtime: ${sourceStats.mtime.toISOString()})`);
+
+  // Step 3: Find and replace all better_sqlite3.node in standalone resources
   // macOS: <appOutDir>/CodePilot.app/Contents/Resources/standalone/...
   // Windows/Linux: <appOutDir>/resources/standalone/...
   const searchRoots = [
-    // macOS paths
     path.join(appOutDir, 'CodePilot.app', 'Contents', 'Resources', 'standalone'),
     path.join(appOutDir, 'Contents', 'Resources', 'standalone'),
-    // Windows/Linux paths
     path.join(appOutDir, 'resources', 'standalone'),
   ];
 
@@ -47,8 +92,10 @@ module.exports = async function afterPack(context) {
       if (entry.isDirectory()) {
         walkAndReplace(fullPath);
       } else if (entry.name === 'better_sqlite3.node') {
-        console.log(`[afterPack] Replacing ${fullPath}`);
+        const beforeSize = fs.statSync(fullPath).size;
         fs.copyFileSync(rebuiltSource, fullPath);
+        const afterSize = fs.statSync(fullPath).size;
+        console.log(`[afterPack] Replaced ${fullPath} (${beforeSize} -> ${afterSize} bytes)`);
         replaced++;
       }
     }
@@ -59,13 +106,14 @@ module.exports = async function afterPack(context) {
   }
 
   if (replaced > 0) {
-    console.log(`[afterPack] Replaced ${replaced} better_sqlite3.node file(s) with Electron-compatible build`);
+    console.log(`[afterPack] Successfully replaced ${replaced} better_sqlite3.node file(s) with Electron ABI build`);
   } else {
-    console.warn('[afterPack] No better_sqlite3.node files found in standalone resources');
-    // List the resources dir for debugging
+    console.warn('[afterPack] WARNING: No better_sqlite3.node files found in standalone resources!');
     for (const root of searchRoots) {
       if (fs.existsSync(root)) {
         console.log(`[afterPack] Contents of ${root}:`, fs.readdirSync(root).slice(0, 20));
+      } else {
+        console.log(`[afterPack] Path does not exist: ${root}`);
       }
     }
   }