fix(portability): aipass init UTF-8 stdout on Windows + CI e2e lane (DPLAN-0194)

The real T1 Windows bug (diagnosed via the now-reverted error-surfacing
probe): aipass init scaffolds fine, then crashes printing its success
banner — Rich writes the success glyphs through a cp1252 stdout
(UnicodeEncodeError 'charmap'). Same class as the drone fix. The aipass
entry point now reconfigure()s stdout/stderr to UTF-8 in place on Windows.

Also: ci.yml's broad 'pytest --rootdir=.' swept in tests/e2e (which build
a wheel via the dedicated e2e-wheel.yml), failing the unit lane since the
harness landed; now --ignore=tests/e2e in both pytest jobs.

route_command error-surfacing probe reverted to honor 'no function change'
(the masked-error mislabel is noted as a separate @aipass recommendation).

Local: e2e 14/14 green, aipass units 24/24, ruff clean.

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

.github/workflows/ci.yml

@@ -38,7 +38,9 @@ jobs:
       - run: |
           python -m pip install --upgrade pip
           pip install -e ".[dev]"
-      - run: coverage run -m pytest -v --tb=short --rootdir=.
+      # tests/e2e build a wheel + clean venv per the dedicated e2e-wheel.yml
+      # workflow — they are not part of the fast unit lane.
+      - run: coverage run -m pytest -v --tb=short --rootdir=. --ignore=tests/e2e
 
   standards:
     name: seedgo-audit
@@ -66,7 +68,7 @@ jobs:
       - run: |
           python -m pip install --upgrade pip
           pip install -e ".[dev]"
-      - run: coverage run -m pytest --rootdir=.
+      - run: coverage run -m pytest --rootdir=. --ignore=tests/e2e
       - run: coverage xml
       - uses: codecov/codecov-action@e79a6962e0d4c0c17b229090214935d2e33f8354 # v6.0.1
         with:

CHANGELOG.md

@@ -70,18 +70,25 @@ and this project uses [Calendar Versioning](https://calver.org/) in the format
   Windows (the old Windows CI ran an editable install, `aipass`-less, and only
   routed to in-process modules, so both paths had zero Windows coverage). Pure
   portability fixes — Linux/macOS behaviour is unchanged.
-  - **`aipass init` failed on Windows with a misleading "Unknown command: init".**
-    `_preflight_check` walks every ancestor of CWD up to the filesystem root
-    calling `iterdir()`/`is_file()`; at the Windows drive root a locked system
-    entry (e.g. `pagefile.sys`) raises `OSError`, which the CLI's `route_command`
-    swallowed and mislabeled. The ancestor walk now skips un-enumerable /
-    un-stattable entries (logged), so init proceeds normally.
-  - **`drone @branch` crashed on Windows with `UnicodeEncodeError ('charmap')`.**
-    `drone` resolved + subprocessed the branch correctly, then crashed *printing*
-    the captured output: Rich wrote Unicode through a cp1252 stdout. The existing
+  - **`aipass init` crashed on Windows (surfaced as a misleading "Unknown
+    command: init").** Init scaffolded the project correctly, then crashed
+    *printing its `✓ Project initialized` banner* — Rich wrote the ✓/box glyphs
+    through a cp1252 stdout, raising `UnicodeEncodeError ('charmap')`; the error
+    handler's `✗` message hit the same wall, bubbling up to the command router
+    which mislabeled it. The `aipass` entry point now reconfigures stdout/stderr
+    to UTF-8 in place on Windows. (The init preflight ancestor-walk was also
+    hardened to skip un-enumerable Windows drive-root entries — defensive, not
+    the trigger.)
+  - **`drone @branch` crashed on Windows with the same `UnicodeEncodeError
+    ('charmap')`.** `drone` resolved + subprocessed the branch correctly, then
+    crashed *printing* the captured output through cp1252 stdout. The existing
     `PYTHONUTF8` guard only affected child interpreters, not the live process
     streams — `drone`'s entry point now also `reconfigure()`s stdout/stderr to
-    UTF-8 in place. (DPLAN-0194)
+    UTF-8 in place.
+  - **CI unit lane no longer runs the e2e wheel tests.** `ci.yml`'s
+    `pytest --rootdir=.` swept in `tests/e2e/` (which build a wheel per the
+    dedicated `e2e-wheel.yml`), failing the unit lane; it now `--ignore`s them.
+    (DPLAN-0194)
 - **A release merge can no longer destroy the `dev` branch** — `drone @git merge`
   passed `--delete-branch` to `gh pr merge` unconditionally, so merging a
   `dev`→`main` PR deleted the persistent `dev` branch on the remote and stranded

src/aipass/aipass/apps/aipass.py

@@ -15,12 +15,25 @@ Auto-discovery architecture:
 - No manual imports or routing needed
 """
 
+import os
 import sys
 import importlib
-import traceback
 from pathlib import Path
 from typing import List, Any
 
+# Windows terminals/pipes default to cp1252, which can't encode the Unicode
+# Rich emits (✓/✗, box-drawing, arrows). PYTHONUTF8 only affects child
+# interpreters, not this process's already-open stdout/stderr — so we also
+# reconfigure the live streams to UTF-8 in place (Python 3.7+). Without this,
+# `aipass init` scaffolds correctly but crashes printing its success banner
+# with UnicodeEncodeError ('charmap') on Windows. Mirrors drone/cli.py.
+if sys.platform == "win32":
+    os.environ.setdefault("PYTHONUTF8", "1")  # for child subprocesses
+    for _stream in (sys.stdout, sys.stderr):
+        _reconfigure = getattr(_stream, "reconfigure", None)
+        if _reconfigure is not None:
+            _reconfigure(encoding="utf-8", errors="replace")
+
 from aipass.prax import logger
 
 # =============================================================================
@@ -60,12 +73,7 @@ def route_command(command: str, args: List[str], modules: List[Any]) -> bool:
             if module.handle_command(command, args):
                 return True
         except Exception as e:
-            # A module that owns this command but fails must not be masked as
-            # "Unknown command" — surface the real error (and traceback) to
-            # stderr so failures are diagnosable instead of silently swallowed.
             logger.error(f"[AIPASS] Module {module.__name__} error: {e}")
-            print(f"[AIPASS] {module.__name__.split('.')[-1]} failed: {e}", file=sys.stderr)
-            traceback.print_exc(file=sys.stderr)
     return False