fix: harden error handling, fix TOCTOU races, and improve test accuracy

Core library fixes:
- session-manager.js: wrap all statSync calls in try-catch to prevent
  TOCTOU crashes when files are deleted between readdir and stat
- session-manager.js: use birthtime||ctime fallback for Linux compat
- session-manager.js: remove redundant existsSync before readFile
- utils.js: fix findFiles TOCTOU race on statSync inside readdir loop

Hook improvements:
- Add 1MB stdin buffer limits to all PostToolUse hooks to prevent
  unbounded memory growth from large payloads
- suggest-compact.js: use fd-based atomic read+write for counter file
  to reduce race window between concurrent invocations
- session-end.js: log when transcript file is missing, check
  replaceInFile return value for failed timestamp updates
- start-observer.sh: log claude CLI failures instead of silently
  swallowing them, check observations file exists before analysis

Test fixes:
- Fix blocking hook tests to send matching input (dev server command)
  and expect correct exit code 2 instead of 1

scripts/hooks/check-console-log.js

@@ -26,10 +26,13 @@ const EXCLUDED_PATTERNS = [
   /__mocks__\//,
 ];
 
+const MAX_STDIN = 1024 * 1024; // 1MB limit
 let data = '';
 
 process.stdin.on('data', chunk => {
-  data += chunk;
+  if (data.length < MAX_STDIN) {
+    data += chunk;
+  }
 });
 
 process.stdin.on('end', () => {

scripts/hooks/post-edit-console-warn.js

@@ -11,10 +11,13 @@
 
 const fs = require('fs');
 
+const MAX_STDIN = 1024 * 1024; // 1MB limit
 let data = '';
 
 process.stdin.on('data', chunk => {
-  data += chunk;
+  if (data.length < MAX_STDIN) {
+    data += chunk;
+  }
 });
 
 process.stdin.on('end', () => {

scripts/hooks/post-edit-format.js

@@ -11,10 +11,13 @@
 const { execFileSync } = require('child_process');
 const fs = require('fs');
 
+const MAX_STDIN = 1024 * 1024; // 1MB limit
 let data = '';
 
 process.stdin.on('data', chunk => {
-  data += chunk;
+  if (data.length < MAX_STDIN) {
+    data += chunk;
+  }
 });
 
 process.stdin.on('end', () => {

scripts/hooks/post-edit-typecheck.js

@@ -13,10 +13,13 @@ const { execFileSync } = require('child_process');
 const fs = require('fs');
 const path = require('path');
 
+const MAX_STDIN = 1024 * 1024; // 1MB limit
 let data = '';
 
 process.stdin.on('data', chunk => {
-  data += chunk;
+  if (data.length < MAX_STDIN) {
+    data += chunk;
+  }
 });
 
 process.stdin.on('end', () => {

scripts/hooks/session-end.js

@@ -99,17 +99,24 @@ async function main() {
   const transcriptPath = process.env.CLAUDE_TRANSCRIPT_PATH;
   let summary = null;
 
-  if (transcriptPath && fs.existsSync(transcriptPath)) {
-    summary = extractSessionSummary(transcriptPath);
+  if (transcriptPath) {
+    if (fs.existsSync(transcriptPath)) {
+      summary = extractSessionSummary(transcriptPath);
+    } else {
+      log(`[SessionEnd] Transcript not found: ${transcriptPath}`);
+    }
   }
 
   if (fs.existsSync(sessionFile)) {
     // Update existing session file
-    replaceInFile(
+    const updated = replaceInFile(
       sessionFile,
       /\*\*Last Updated:\*\*.*/,
       `**Last Updated:** ${currentTime}`
     );
+    if (!updated) {
+      log(`[SessionEnd] Failed to update timestamp in ${sessionFile}`);
+    }
 
     // If we have a new summary and the file still has the blank template, replace it
     if (summary) {

scripts/hooks/suggest-compact.js

@@ -13,10 +13,10 @@
  * - Compact after completing a milestone, before starting next
  */
 
+const fs = require('fs');
 const path = require('path');
 const {
   getTempDir,
-  readFile,
   writeFile,
   log
 } = require('../lib/utils');
@@ -32,16 +32,28 @@ async function main() {
   let count = 1;
 
   // Read existing count or start at 1
-  const existing = readFile(counterFile);
-  if (existing) {
-    const parsed = parseInt(existing.trim(), 10);
-    // Guard against NaN from corrupted counter file
-    count = Number.isFinite(parsed) ? parsed + 1 : 1;
+  // Use fd-based read+write to reduce (but not eliminate) race window
+  // between concurrent hook invocations
+  try {
+    const fd = fs.openSync(counterFile, 'a+');
+    try {
+      const buf = Buffer.alloc(64);
+      const bytesRead = fs.readSync(fd, buf, 0, 64, 0);
+      if (bytesRead > 0) {
+        const parsed = parseInt(buf.toString('utf8', 0, bytesRead).trim(), 10);
+        count = Number.isFinite(parsed) ? parsed + 1 : 1;
+      }
+      // Truncate and write new value
+      fs.ftruncateSync(fd, 0);
+      fs.writeSync(fd, String(count), 0);
+    } finally {
+      fs.closeSync(fd);
+    }
+  } catch {
+    // Fallback: just use writeFile if fd operations fail
+    writeFile(counterFile, String(count));
   }
 
-  // Save updated count
-  writeFile(counterFile, String(count));
-
   // Suggest compact after threshold tool calls
   if (count === threshold) {
     log(`[StrategicCompact] ${threshold} tool calls reached - consider /compact if transitioning phases`);

scripts/lib/session-manager.js

@@ -58,10 +58,6 @@ function getSessionPath(filename) {
  * @returns {string|null} Session content or null if not found
  */
 function getSessionContent(sessionPath) {
-  if (!fs.existsSync(sessionPath)) {
-    return null;
-  }
-
   return readFile(sessionPath);
 }
 
@@ -217,8 +213,14 @@ function getAllSessions(options = {}) {
 
     const sessionPath = path.join(sessionsDir, filename);
 
-    // Get file stats
-    const stats = fs.statSync(sessionPath);
+    // Get file stats (wrapped in try-catch to handle TOCTOU race where
+    // file is deleted between readdirSync and statSync)
+    let stats;
+    try {
+      stats = fs.statSync(sessionPath);
+    } catch {
+      continue; // File was deleted between readdir and stat
+    }
 
     sessions.push({
       ...metadata,
@@ -226,7 +228,7 @@ function getAllSessions(options = {}) {
       hasContent: stats.size > 0,
       size: stats.size,
       modifiedTime: stats.mtime,
-      createdTime: stats.birthtime
+      createdTime: stats.birthtime || stats.ctime
     });
   }
 
@@ -278,14 +280,19 @@ function getSessionById(sessionId, includeContent = false) {
     }
 
     const sessionPath = path.join(sessionsDir, filename);
-    const stats = fs.statSync(sessionPath);
+    let stats;
+    try {
+      stats = fs.statSync(sessionPath);
+    } catch {
+      return null; // File was deleted between readdir and stat
+    }
 
     const session = {
       ...metadata,
       sessionPath,
       size: stats.size,
       modifiedTime: stats.mtime,
-      createdTime: stats.birthtime
+      createdTime: stats.birthtime || stats.ctime
     };
 
     if (includeContent) {
@@ -319,11 +326,12 @@ function getSessionTitle(sessionPath) {
  * @returns {string} Formatted size (e.g., "1.2 KB")
  */
 function getSessionSize(sessionPath) {
-  if (!fs.existsSync(sessionPath)) {
+  let stats;
+  try {
+    stats = fs.statSync(sessionPath);
+  } catch {
     return '0 B';
   }
-
-  const stats = fs.statSync(sessionPath);
   const size = stats.size;
 
   if (size < 1024) return `${size} B`;
@@ -387,7 +395,11 @@ function deleteSession(sessionPath) {
  * @returns {boolean} True if session exists
  */
 function sessionExists(sessionPath) {
-  return fs.existsSync(sessionPath) && fs.statSync(sessionPath).isFile();
+  try {
+    return fs.statSync(sessionPath).isFile();
+  } catch {
+    return false;
+  }
 }
 
 module.exports = {

scripts/lib/utils.js

@@ -168,14 +168,19 @@ function findFiles(dir, pattern, options = {}) {
         const fullPath = path.join(currentDir, entry.name);
 
         if (entry.isFile() && regex.test(entry.name)) {
+          let stats;
+          try {
+            stats = fs.statSync(fullPath);
+          } catch {
+            continue; // File deleted between readdir and stat
+          }
+
           if (maxAge !== null) {
-            const stats = fs.statSync(fullPath);
             const ageInDays = (Date.now() - stats.mtimeMs) / (1000 * 60 * 60 * 24);
             if (ageInDays <= maxAge) {
               results.push({ path: fullPath, mtime: stats.mtimeMs });
             }
           } else {
-            const stats = fs.statSync(fullPath);
             results.push({ path: fullPath, mtime: stats.mtimeMs });
           }
         } else if (entry.isDirectory() && recursive) {