fix(server): harden sherpa native loading and centralize runtime env

packages/cli/src/commands/daemon/local-daemon.ts

@@ -3,6 +3,7 @@ import { closeSync, existsSync, openSync, readFileSync, rmSync } from 'node:fs'
 import { createRequire } from 'node:module'
 import path from 'node:path'
 import { loadConfig, resolvePaseoHome } from '@getpaseo/server'
+import { applySherpaLoaderEnv } from './sherpa-env.js'
 
 export interface DaemonStartOptions {
   port?: string
@@ -280,6 +281,7 @@ export async function startLocalDaemonDetached(
   }
 
   const childEnv: NodeJS.ProcessEnv = { ...process.env }
+  applySherpaLoaderEnv(childEnv)
   if (options.home) {
     childEnv.PASEO_HOME = options.home
   }

packages/cli/src/commands/daemon/sherpa-env.ts

@@ -0,0 +1,53 @@
+import { spawnSync } from 'node:child_process'
+import {
+  applySherpaLoaderEnv as applySherpaLoaderEnvFromServer,
+  resolveSherpaLoaderEnv,
+} from '@getpaseo/server'
+
+const SHERPA_ENV_BOOTSTRAPPED = 'PASEO_SHERPA_ENV_BOOTSTRAPPED'
+
+export function applySherpaLoaderEnv(env: NodeJS.ProcessEnv): {
+  changed: boolean
+  key: 'LD_LIBRARY_PATH' | 'DYLD_LIBRARY_PATH' | 'PATH' | null
+  libDir: string | null
+} {
+  const result = applySherpaLoaderEnvFromServer(env)
+  return {
+    changed: result.changed,
+    key: result.key,
+    libDir: result.libDir,
+  }
+}
+
+export function reexecWithSherpaLoaderEnvIfNeeded(): never | void {
+  const resolved = resolveSherpaLoaderEnv()
+  if (!resolved) {
+    return
+  }
+  if (process.env[SHERPA_ENV_BOOTSTRAPPED] === '1') {
+    return
+  }
+
+  const envCopy: NodeJS.ProcessEnv = { ...process.env }
+  const applied = applySherpaLoaderEnvFromServer(envCopy)
+  const updatedValue = applied.key ? envCopy[applied.key] ?? '' : ''
+  if (applied.key && updatedValue === (process.env[applied.key] ?? '')) {
+    return
+  }
+
+  const env: NodeJS.ProcessEnv = {
+    ...envCopy,
+    [SHERPA_ENV_BOOTSTRAPPED]: '1',
+  }
+
+  const result = spawnSync(process.execPath, process.argv.slice(1), {
+    env,
+    stdio: 'inherit',
+  })
+
+  if (result.error) {
+    throw result.error
+  }
+
+  process.exit(result.status ?? 1)
+}

packages/cli/src/commands/daemon/start.ts

@@ -12,6 +12,7 @@ import {
   startLocalDaemonDetached,
   type DaemonStartOptions as StartOptions,
 } from './local-daemon.js'
+import { reexecWithSherpaLoaderEnvIfNeeded } from './sherpa-env.js'
 import { getErrorMessage } from '../../utils/errors.js'
 
 export type { DaemonStartOptions as StartOptions } from './local-daemon.js'
@@ -79,6 +80,8 @@ export async function runStart(options: StartOptions): Promise<void> {
     return
   }
 
+  reexecWithSherpaLoaderEnvIfNeeded()
+
   if (options.home) {
     process.env.PASEO_HOME = options.home
   }