fix: log bootstrap errors to daemon.log and add layout debug logging

- Log fatal errors during daemon bootstrap and startup to pino (daemon.log)
  instead of only writing to stderr, which is invisible on Windows desktop
- Delay process.exit to let pino async streams flush
- Make voice MCP bridge script resolution non-fatal (warn + disable instead
  of crashing the daemon)
- Add PASEO_ELECTRON_FLAGS env var for passing Chromium flags on Linux
- Add layout debug logging to AppContainer for diagnosing sidebar issues

packages/server/src/server/bootstrap.ts

@@ -133,21 +133,28 @@ import { resolveVoiceMcpBridgeFromRuntime } from "./voice-mcp-bridge-command.js"
 
 type AgentMcpTransportMap = Map<string, StreamableHTTPServerTransport>;
 
-function resolveVoiceMcpBridgeCommand(logger: Logger): { command: string; baseArgs: string[] } {
-  const decision = resolveVoiceMcpBridgeFromRuntime({
-    bootstrapModuleUrl: import.meta.url,
-    execPath: process.execPath,
-    explicitScriptPath: process.env.PASEO_MCP_STDIO_SOCKET_BRIDGE_SCRIPT,
-  });
-  logger.info(
-    {
-      source: decision.source,
-      command: decision.resolved.command,
-      baseArgs: decision.resolved.baseArgs,
-    },
-    "Resolved voice MCP bridge command",
-  );
-  return decision.resolved;
+function resolveVoiceMcpBridgeCommand(
+  logger: Logger,
+): { command: string; baseArgs: string[] } | null {
+  try {
+    const decision = resolveVoiceMcpBridgeFromRuntime({
+      bootstrapModuleUrl: import.meta.url,
+      execPath: process.execPath,
+      explicitScriptPath: process.env.PASEO_MCP_STDIO_SOCKET_BRIDGE_SCRIPT,
+    });
+    logger.info(
+      {
+        source: decision.source,
+        command: decision.resolved.command,
+        baseArgs: decision.resolved.baseArgs,
+      },
+      "Resolved voice MCP bridge command",
+    );
+    return decision.resolved;
+  } catch (err) {
+    logger.warn({ err }, "Voice MCP bridge script not available — voice MCP via stdio disabled");
+    return null;
+  }
 }
 
 export type PaseoOpenAIConfig = OpenAiSpeechProviderConfig;
@@ -669,14 +676,16 @@ export async function createPaseoDaemon(
       speechService,
       terminalManager,
       {
-        voiceAgentMcpStdio: {
-          command: voiceMcpBridgeCommand.command,
-          baseArgs: [...voiceMcpBridgeCommand.baseArgs],
-          env: {
-            ELECTRON_RUN_AS_NODE: "1",
-            PASEO_HOME: config.paseoHome,
-          },
-        },
+        voiceAgentMcpStdio: voiceMcpBridgeCommand
+          ? {
+              command: voiceMcpBridgeCommand.command,
+              baseArgs: [...voiceMcpBridgeCommand.baseArgs],
+              env: {
+                ELECTRON_RUN_AS_NODE: "1",
+                PASEO_HOME: config.paseoHome,
+              },
+            }
+          : null,
         ensureVoiceMcpSocketForAgent: (agentId) =>
           voiceMcpBridgeManager?.ensureBridgeForCaller(agentId) ??
           Promise.reject(new Error("Voice MCP bridge manager is not initialized")),

packages/server/src/server/index.ts

@@ -143,6 +143,7 @@ async function main() {
       logger.error({ pid: err.existingLock?.pid }, err.message);
       process.exit(1);
     }
+    logger.fatal({ err }, "Daemon bootstrap failed");
     throw err;
   }
 
@@ -153,6 +154,7 @@ async function main() {
       logger.error({ pid: err.existingLock?.pid }, err.message);
       process.exit(1);
     }
+    logger.fatal({ err }, "Daemon failed to start listening");
     throw err;
   }
 
@@ -171,10 +173,9 @@ async function main() {
 }
 
 main().catch((err) => {
-  if (process.env.PASEO_DEBUG === "1") {
-    process.stderr.write(`${err instanceof Error ? (err.stack ?? err.message) : String(err)}\n`);
-  } else {
-    process.stderr.write(`${err instanceof Error ? err.message : String(err)}\n`);
-  }
-  process.exit(1);
+  process.stderr.write(`${err instanceof Error ? (err.stack ?? err.message) : String(err)}\n`);
+  // Give pino streams a moment to flush the fatal log entry to daemon.log
+  // before the process exits. Without this, async file streams may lose the
+  // last few entries that explain why the daemon crashed.
+  setTimeout(() => process.exit(1), 200);
 });