Fix boot crash on compose-passed empty setup variables

main.ts parsed process.env raw, so the compose passthroughs
(SETUP_DEFAULT_LOCALE: "") failed the enum parse and crash-looped the
Test api. Route main.ts through the same loadApiEnv as AppConfig, which
overlays the secret store and drops empty strings.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_01EwZ4jR4KFAPvpjWevfUGX1

apps/api/src/config/app-config.service.ts

@@ -3,15 +3,24 @@ import { ApiEnv, apiEnvSchema, parseEnv } from '@dorfteich/shared';
 
 import { overlayEnv, readSecretsFile } from './secret-store';
 
+/**
+ * The one way to resolve the api environment: secrets the setup wizard
+ * persisted (SMTP credentials) extend the process env, explicit env always
+ * wins, and empty strings count as unset (secret-store.ts). main.ts and
+ * AppConfig MUST both use this — compose passes optional variables as ""
+ * and a raw `parseEnv(schema, process.env)` would fail on enum fields.
+ */
+export function loadApiEnv(): ApiEnv {
+  const secretsFile = apiEnvSchema.shape.SECRETS_FILE.parse(process.env.SECRETS_FILE || undefined);
+  const secrets = readSecretsFile(secretsFile);
+  return parseEnv(apiEnvSchema, overlayEnv(process.env, secrets));
+}
+
 @Injectable()
 export class AppConfig {
   readonly env: ApiEnv;
 
   constructor() {
-    // Secrets the setup wizard persisted (SMTP credentials) extend the
+    this.env = loadApiEnv();
-    // environment; explicit process env always wins (secret-store.ts).
-    const secretsFile = apiEnvSchema.shape.SECRETS_FILE.parse(process.env.SECRETS_FILE);
-    const secrets = readSecretsFile(secretsFile);
-    this.env = parseEnv(apiEnvSchema, overlayEnv(process.env, secrets));
   }
 }

apps/api/src/config/app-config.test.ts

@@ -0,0 +1,44 @@
+import { afterEach, describe, expect, it } from 'vitest';
+
+import { loadApiEnv } from './app-config.service';
+
+/**
+ * Regression for the Test-stage boot crash after #80: compose passes
+ * optional variables as empty strings (`SETUP_DEFAULT_LOCALE: ${…:-}`),
+ * and a raw parse of process.env fails on enum fields. loadApiEnv must
+ * treat them as unset — in main.ts exactly like in AppConfig.
+ */
+describe('loadApiEnv', () => {
+  const touched = [
+    'SETUP_DEFAULT_LOCALE',
+    'SETUP_REGISTRATION_MODE',
+    'SMTP_HOST',
+    'SMTP_PORT',
+    'SECRETS_FILE',
+    'DATABASE_URL',
+  ] as const;
+  const saved = Object.fromEntries(touched.map((key) => [key, process.env[key]]));
+
+  afterEach(() => {
+    for (const key of touched) {
+      if (saved[key] === undefined) delete process.env[key];
+      else process.env[key] = saved[key];
+    }
+  });
+
+  it('treats compose-passed empty strings as unset', () => {
+    process.env.DATABASE_URL = 'postgresql://user:pass@localhost:5432/db';
+    process.env.SETUP_DEFAULT_LOCALE = '';
+    process.env.SETUP_REGISTRATION_MODE = '';
+    process.env.SMTP_HOST = '';
+    process.env.SMTP_PORT = '';
+    process.env.SECRETS_FILE = '';
+
+    const env = loadApiEnv();
+    expect(env.SETUP_DEFAULT_LOCALE).toBeUndefined();
+    expect(env.SETUP_REGISTRATION_MODE).toBeUndefined();
+    expect(env.SMTP_HOST).toBe('localhost'); // schema default, not ""
+    expect(env.SMTP_PORT).toBe(1025);
+    expect(env.SECRETS_FILE).toBe('./data/secrets.env');
+  });
+});

apps/api/src/main.ts

@@ -3,11 +3,10 @@ import { execFileSync } from 'node:child_process';
 import cookieParser from 'cookie-parser';
 import { NestFactory } from '@nestjs/core';
 import type { NestExpressApplication } from '@nestjs/platform-express';
-import { apiEnvSchema, parseEnv } from '@dorfteich/shared';
 import { Logger } from 'nestjs-pino';
 
 import { AppModule } from './app.module';
-import { AppConfig } from './config/app-config.service';
+import { AppConfig, loadApiEnv } from './config/app-config.service';
 
 /**
  * Apply pending migrations before the application accepts traffic, so
@@ -22,7 +21,7 @@ function runMigrations(): void {
 async function bootstrap(): Promise<void> {
   // Validate the environment before doing anything with it; this throws a
   // readable list of problems and prevents a half-started process.
-  const env = parseEnv(apiEnvSchema, process.env);
+  const env = loadApiEnv();
   if (env.MIGRATE_ON_START) {
     runMigrations();
   }