fix(ui): ignore inherited esbuild binary overrides

hermes_cli/main.py

@@ -2189,6 +2189,15 @@ def _ensure_tui_workspace(tui_dir: Path) -> None:
     sys.exit(1)
 
 
+def _npm_install_env(env: dict[str, str] | None = None) -> dict[str, str]:
+    """Build a clean environment for installing the pinned UI toolchain."""
+    run_env = {**os.environ, **(env or {}), "CI": "1"}
+    # esbuild treats this as an executable override. If a shell points it at a
+    # different release, the pinned package's postinstall rejects that binary.
+    run_env.pop("ESBUILD_BINARY_PATH", None)
+    return run_env
+
+
 def _make_tui_argv(tui_dir: Path, tui_dev: bool) -> tuple[list[str], Path]:
     """TUI: --dev → tsx src; else node dist (HERMES_TUI_DIR prebuilt or esbuild)."""
     _ensure_tui_node()
@@ -2319,7 +2328,7 @@ def _make_tui_argv(tui_dir: Path, tui_dev: bool) -> tuple[list[str], Path]:
                 text=True,
                 encoding="utf-8",
                 errors="replace",
-                env={**with_hermes_node_path(), "CI": "1"},
+                env=_npm_install_env(with_hermes_node_path()),
             )
 
         result = _run_tui_install()
@@ -5942,7 +5951,7 @@ def _run_npm_install_deterministic(
     # unicode-animations' postinstall animates to /dev/tty (bypasses
     # --silent/capture_output). It no-ops when CI is set — same as the TUI
     # install path and nix/lib.nix npm ci hooks.
-    run_env = {**os.environ, **(env or {}), "CI": "1"}
+    run_env = _npm_install_env(env)
 
     def _run(cmd: list[str]) -> subprocess.CompletedProcess:
         return _run_npm_watching_for_engine_failure(

tests/hermes_cli/test_tui_npm_install.py

@@ -137,14 +137,15 @@ def test_no_stray_lockfiles_in_workspace_subdirs(main_mod) -> None:
     )
 
 
-def test_make_tui_argv_omits_workspace_when_tui_has_own_lockfile(
+def test_make_tui_argv_omits_workspace_and_scrubs_esbuild_override(
     tmp_path: Path, main_mod, monkeypatch
 ) -> None:
     """When ui-tui/ has its own package-lock.json, _workspace_root returns
     tui_dir itself.  npm install --workspace ui-tui would fail in that case
     because npm cannot find a workspace named "ui-tui" inside ui-tui/.
     The fix omits --workspace and runs plain npm install from tui_dir.
-    See #42973.
+    See #42973. The npm child must also ignore an inherited esbuild binary
+    override: a version mismatch makes esbuild's postinstall abort (#87405).
     """
     tui_dir = tmp_path / "ui-tui"
     tui_dir.mkdir()
@@ -156,6 +157,7 @@ def test_make_tui_argv_omits_workspace_when_tui_has_own_lockfile(
 
     monkeypatch.delenv("TERMUX_VERSION", raising=False)
     monkeypatch.setenv("PREFIX", "/usr")
+    monkeypatch.setenv("ESBUILD_BINARY_PATH", "/opt/esbuild-0.28.2")
     monkeypatch.setattr(main_mod, "_tui_need_npm_install", lambda _root: True)
     monkeypatch.setattr(main_mod.shutil, "which", lambda name: f"/bin/{name}")
     calls = []
@@ -173,6 +175,8 @@ def test_make_tui_argv_omits_workspace_when_tui_has_own_lockfile(
     assert "--workspace" not in install_cmd, (
         f"npm install should omit --workspace when tui_dir has its own lockfile, got: {install_cmd}"
     )
-    assert install_cmd[:2] == ["/bin/npm", "install"]
+    assert Path(install_cmd[0]).name in {"npm", "npm.cmd"}
+    assert install_cmd[1] == "install"
     # cwd must be tui_dir (standalone), not parent
     assert calls[0][1]["cwd"] == str(tui_dir)
+    assert "ESBUILD_BINARY_PATH" not in calls[0][1]["env"]

tests/hermes_cli/test_web_ui_build.py

@@ -123,7 +123,7 @@ class TestBuildWebUISkipsWhenFresh:
 
 
 
-    def test_web_install_omits_workspace_when_web_has_own_lockfile(
+    def test_web_install_omits_workspace_and_scrubs_esbuild_override(
         self, tmp_path, monkeypatch
     ):
         """web/ with its own lockfile => _workspace_root returns web_dir, so
@@ -132,13 +132,16 @@ class TestBuildWebUISkipsWhenFresh:
         Symmetric to the TUI fix in test_tui_npm_install.py. See #42973.
 
         With web's own lockfile present at cwd, _run_npm_install_deterministic
-        uses ``npm ci`` (not ``npm install``).
+        uses ``npm ci`` (not ``npm install``). The shared installer must also
+        remove an inherited esbuild binary override so package/binary versions
+        cannot diverge (#87405).
         """
         web_dir, _ = _make_web_dir(tmp_path)
         (web_dir / "package-lock.json").write_text("{}", encoding="utf-8")
         (tmp_path / "package-lock.json").write_text("{}", encoding="utf-8")
         monkeypatch.delenv("TERMUX_VERSION", raising=False)
         monkeypatch.setenv("PREFIX", "/usr")
+        monkeypatch.setenv("ESBUILD_BINARY_PATH", "/opt/esbuild-0.28.2")
 
         install_cp = __import__("subprocess").CompletedProcess([], 0, stdout="", stderr="")
         build_cp = __import__("subprocess").CompletedProcess([], 0, stdout="", stderr="")
@@ -150,8 +153,10 @@ class TestBuildWebUISkipsWhenFresh:
         assert result is True
         args, kwargs = mock_run.call_args
         assert "--workspace" not in args[0]
-        assert args[0] == ["/usr/bin/npm", "ci", "--include=dev", "--silent", "--prefer-offline"]
+        assert Path(args[0][0]).name in {"npm", "npm.cmd"}
+        assert args[0][1:] == ["ci", "--include=dev", "--silent", "--prefer-offline"]
         assert kwargs["cwd"] == web_dir
+        assert "ESBUILD_BINARY_PATH" not in kwargs["env"]
 
     def test_workspace_root_install_names_update_closure(self, tmp_path, monkeypatch):
         """From the workspace root, _build_web_ui must install the SAME