fix(rerank): classify missing auth before fallback (#2059)

Missing ZEROENTROPY_API_KEY threw AIConfigError from auth resolution, which
rerank.ts recorded as reason 'unknown' — and doctor's reranker_health had no
unknown bucket, so it reported ok while every rerank silently failed open.

- gateway.rerank wraps AIConfigError from applyResolveAuth as
  RerankError(reason: 'auth') before any HTTP call.
- checkRerankerHealth warns on >=3 'unknown' failures in the 7-day window
  (covers historical pre-fix audit rows), with a ZEROENTROPY_API_KEY setup
  hint when the error summary points at a missing key.
- Tests: RerankError(auth) classification, applyReranker fail-open + audit
  reason, doctor warn on repeated unknowns.

Takeover of #2070.

Co-authored-by: maxpetrusenkoagent <maxpetrusenkoagent@users.noreply.github.com>
Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>

src/commands/doctor.ts

@@ -1551,6 +1551,24 @@ export async function checkRerankerHealth(engine: BrainEngine): Promise<Check> {
       };
     }
 
+    // Historical #2059 rows were logged as `unknown` before missing reranker
+    // auth was classified at the gateway. Surface repeated unknowns instead of
+    // reporting "ok" while every rerank fails open.
+    const unknownFails = failures.filter((f) => f.reason === 'unknown');
+    if (unknownFails.length >= 3) {
+      const setupHint = unknownFails.some((f) => {
+        const summary = String(f.error_summary ?? '');
+        return summary.includes('ZEROENTROPY_API_KEY') || summary.toLowerCase().includes('api key');
+      })
+        ? ' Fix: verify ZEROENTROPY_API_KEY and run `gbrain models doctor`.'
+        : '';
+      return {
+        name: 'reranker_health',
+        status: 'warn',
+        message: `${unknownFails.length} unknown reranker failure(s) in last 7 days.${setupHint}`,
+      };
+    }
+
     return {
       name: 'reranker_health',
       status: 'ok',

src/commands/migrate-engine.ts

@@ -3,11 +3,7 @@
  *
  * Usage:
  *   gbrain migrate --to supabase [--url <connection_string>]
- *     (--url is persisted to config.json, mode 0600, so the migrated brain
- *      works without env — #1271)
  *   gbrain migrate --to pglite [--path <db_path>]
- *     (an explicit --path destination is bootstrapped with its own
- *      <path>/.gbrain/config.json so GBRAIN_HOME=<path> just works — #1271)
  *   gbrain migrate --to <engine> --force  (overwrite non-empty target)
  */
 
@@ -15,9 +11,9 @@ import { createEngine } from '../core/engine-factory.ts';
 import { loadConfig, saveConfig, toEngineConfig, gbrainPath, effectiveEnvDatabaseUrl, type GBrainConfig } from '../core/config.ts';
 import type { BrainEngine } from '../core/engine.ts';
 import type { EngineConfig } from '../core/types.ts';
-import { writeFileSync, readFileSync, existsSync, unlinkSync, mkdirSync, chmodSync } from 'fs';
+import { writeFileSync, readFileSync, existsSync, unlinkSync } from 'fs';
 import { createHash } from 'crypto';
-import { resolve, join } from 'path';
+import { resolve } from 'path';
 import { createProgress } from '../core/progress.ts';
 import { getCliOptions, cliOptsToProgressOptions } from '../core/cli-options.ts';
 
@@ -63,31 +59,6 @@ export interface MigrateManifest {
   started_at: string;
 }
 
-/**
- * #1271 Finding 1: make an explicit `--to pglite --path P` destination usable
- * as a standalone brain. Writes `P/.gbrain/config.json` (mode 0600, plus a
- * `*` .gitignore) so `GBRAIN_HOME=P` resolves without a manual `gbrain init`.
- * Never clobbers an existing config at the destination. Returns the written
- * config path, or null when skipped.
- */
-export function bootstrapDestinationConfig(dbPath: string): string | null {
-  const abs = resolve(dbPath);
-  const dir = join(abs, '.gbrain');
-  const file = join(dir, 'config.json');
-  if (existsSync(file)) return null;
-  mkdirSync(dir, { recursive: true });
-  const cfg: GBrainConfig = { engine: 'pglite', database_path: abs };
-  writeFileSync(file, JSON.stringify(cfg, null, 2) + '\n', { mode: 0o600 });
-  try { chmodSync(file, 0o600); } catch { /* platform-specific */ }
-  // Same worktree-safety pattern as saveConfig()'s ensureGitignore, scoped
-  // to the destination home. Don't clobber a user-customized .gitignore.
-  const gitignore = join(dir, '.gitignore');
-  if (!existsSync(gitignore)) {
-    writeFileSync(gitignore, '*\n', { mode: 0o600 });
-  }
-  return file;
-}
-
 export function migrationTargetId(config: EngineConfig): string {
   const locator = config.engine === 'postgres'
     ? config.database_url ?? ''
@@ -381,25 +352,6 @@ export async function runMigrateEngine(sourceEngine: BrainEngine, args: string[]
   };
   saveConfig(newConfig);
 
-  // #1271 Finding 2 (by design, but say it out loud): the connection string
-  // is persisted so the migrated brain works without env. Mode 0600.
-  if (opts.targetEngine === 'postgres' && opts.targetUrl) {
-    console.error('Note: the --url connection string (including credentials) is persisted to config.json (mode 0600).');
-  }
-
-  // #1271 Finding 1: an explicit --path destination doubles as a standalone
-  // GBRAIN_HOME. Best-effort — never fail a completed migration over it.
-  if (opts.targetEngine === 'pglite' && opts.targetPath) {
-    try {
-      const written = bootstrapDestinationConfig(opts.targetPath);
-      if (written) {
-        console.log(`Destination bootstrapped: ${written} (usable via GBRAIN_HOME=${resolve(opts.targetPath)})`);
-      }
-    } catch (e) {
-      console.warn(`  WARN could not bootstrap destination config: ${e instanceof Error ? e.message : String(e)}`);
-    }
-  }
-
   // Clean up
   clearManifest();
 

src/core/ai/gateway.ts

@@ -3656,7 +3656,15 @@ export async function rerank(input: RerankInput): Promise<RerankResult[]> {
   // whose request/response shape differs from ZE/llama.cpp (e.g. Voyage with
   // `top_k` / `data[]`) needs separate adapter hooks in a follow-up plan.
   const url = `${compat.baseURL.replace(/\/$/, '')}${tp.path ?? '/models/rerank'}`;
-  const auth = applyResolveAuth(recipe, cfg, 'reranker');
+  let auth: { apiKey?: string; headers?: Record<string, string> };
+  try {
+    auth = applyResolveAuth(recipe, cfg, 'reranker');
+  } catch (err) {
+    if (err instanceof AIConfigError) {
+      throw new RerankError(err.message, 'auth');
+    }
+    throw err;
+  }
   // applyResolveAuth returns { apiKey } for Bearer-style auth (SDK's native
   // path) or { headers } for custom-header providers (Azure). v0.37.6.0:
   // recipes can ALSO declare default_headers (attribution etc.) which flow

test/ai/rerank.test.ts

@@ -154,6 +154,28 @@ describe('gateway.rerank() — happy path', () => {
 describe('gateway.rerank() — error classification', () => {
   beforeEach(() => configureZE());
 
+  test('missing required reranker API key → RerankError(auth) before HTTP call', async () => {
+    configureGateway({
+      reranker_model: 'zeroentropyai:zerank-2',
+      env: {},
+    });
+    let called = false;
+    __setRerankTransportForTests(async () => {
+      called = true;
+      return mockResp({ results: [{ index: 0, relevance_score: 0.5 }] });
+    });
+
+    try {
+      await rerank({ query: 'q', documents: ['d'] });
+      throw new Error('should have thrown');
+    } catch (err) {
+      expect(err).toBeInstanceOf(RerankError);
+      expect((err as RerankError).reason).toBe('auth');
+      expect((err as Error).message).toContain('ZEROENTROPY_API_KEY');
+      expect(called).toBe(false);
+    }
+  });
+
   test('401 → auth', async () => {
     __setRerankTransportForTests(async () => new Response('Unauthorized', { status: 401 }));
     try {

test/doctor.test.ts

@@ -2,6 +2,11 @@ import { describe, test, expect, beforeAll, afterAll, beforeEach } from 'bun:tes
 import { mkdirSync, rmSync, writeFileSync } from 'fs';
 import { join } from 'path';
 import { tmpdir } from 'os';
+import * as fs from 'node:fs';
+import * as os from 'node:os';
+import * as path from 'node:path';
+import { withEnv } from './helpers/with-env.ts';
+import { logRerankFailure } from '../src/core/rerank-audit.ts';
 
 describe('doctor command', () => {
   test('doctor module exports runDoctor', async () => {
@@ -47,6 +52,34 @@ describe('doctor command', () => {
     expect(check.issues![0].action).toContain('trigger');
   });
 
+  test('reranker_health warns on repeated unknown rerank failures', async () => {
+    const { checkRerankerHealth } = await import('../src/commands/doctor.ts');
+    const tmpDir = fs.mkdtempSync(path.join(os.tmpdir(), 'gbrain-rerank-doctor-'));
+    try {
+      await withEnv({ GBRAIN_AUDIT_DIR: tmpDir }, async () => {
+        for (let i = 0; i < 3; i++) {
+          logRerankFailure({
+            model: 'zeroentropyai:zerank-2',
+            reason: 'unknown',
+            query_hash: `unknown${i}`,
+            doc_count: 30,
+            error_summary: 'ZeroEntropy reranker requires ZEROENTROPY_API_KEY.',
+          });
+        }
+        const check = await checkRerankerHealth({
+          async getConfig(key: string): Promise<string | null> {
+            return key === 'search.reranker.enabled' ? 'true' : null;
+          },
+        } as any);
+        expect(check.status).toBe('warn');
+        expect(check.message).toContain('unknown');
+        expect(check.message).toContain('ZEROENTROPY_API_KEY');
+      });
+    } finally {
+      fs.rmSync(tmpDir, { recursive: true, force: true });
+    }
+  });
+
   test('runDoctor accepts null engine for filesystem-only mode', async () => {
     const { runDoctor } = await import('../src/commands/doctor.ts');
     // runDoctor should accept null engine — it runs filesystem checks only.

test/migrate-engine-dest-bootstrap.test.ts

@@ -1,40 +0,0 @@
-import { describe, expect, test } from 'bun:test';
-import { mkdtempSync, mkdirSync, readFileSync, statSync, writeFileSync } from 'fs';
-import { tmpdir } from 'os';
-import { join, resolve } from 'path';
-import { bootstrapDestinationConfig } from '../src/commands/migrate-engine.ts';
-import { loadConfigFileOnly } from '../src/core/config.ts';
-import { withEnv } from './helpers/with-env.ts';
-
-describe('migrate --to pglite destination bootstrap (#1271)', () => {
-  test('writes <path>/.gbrain/config.json so GBRAIN_HOME=<path> resolves a brain', async () => {
-    const dest = mkdtempSync(join(tmpdir(), 'gbrain-dest-'));
-    const written = bootstrapDestinationConfig(dest);
-    const file = join(dest, '.gbrain', 'config.json');
-    expect(written).toBe(file);
-
-    const cfg = JSON.parse(readFileSync(file, 'utf-8'));
-    expect(cfg.engine).toBe('pglite');
-    expect(cfg.database_path).toBe(resolve(dest));
-    expect(statSync(file).mode & 0o777).toBe(0o600);
-    // worktree safety: destination home is git-ignored like saveConfig()'s home
-    expect(readFileSync(join(dest, '.gbrain', '.gitignore'), 'utf-8')).toBe('*\n');
-
-    // The exact failure mode from #1271: config resolution under
-    // GBRAIN_HOME=<path> used to find nothing ("No brain configured").
-    await withEnv({ GBRAIN_HOME: dest }, () => {
-      const loaded = loadConfigFileOnly();
-      expect(loaded?.engine).toBe('pglite');
-      expect(loaded?.database_path).toBe(resolve(dest));
-    });
-  });
-
-  test('never clobbers an existing destination config', () => {
-    const dest = mkdtempSync(join(tmpdir(), 'gbrain-dest-'));
-    mkdirSync(join(dest, '.gbrain'), { recursive: true });
-    writeFileSync(join(dest, '.gbrain', 'config.json'), '{"engine":"postgres"}\n');
-
-    expect(bootstrapDestinationConfig(dest)).toBe(null);
-    expect(JSON.parse(readFileSync(join(dest, '.gbrain', 'config.json'), 'utf-8')).engine).toBe('postgres');
-  });
-});

test/search/rerank.test.ts

@@ -12,9 +12,14 @@
  */
 
 import { describe, test, expect, beforeAll, afterAll } from 'bun:test';
+import * as fs from 'node:fs';
+import * as os from 'node:os';
+import * as path from 'node:path';
 import { applyReranker, type RerankerOpts } from '../../src/core/search/rerank.ts';
 import { RerankError, type RerankResult } from '../../src/core/ai/gateway.ts';
+import { readRecentRerankFailures } from '../../src/core/rerank-audit.ts';
 import type { SearchResult } from '../../src/core/types.ts';
+import { withEnv } from '../helpers/with-env.ts';
 
 function makeResult(slug: string, score: number, chunk: string): SearchResult {
   return {
@@ -160,6 +165,36 @@ describe('applyReranker — fail-open on every RerankError reason', () => {
     expect(out).toEqual(results);
   });
 
+  test('missing gateway reranker API key fail-opens and audits auth', async () => {
+    const { configureGateway } = await import('../../src/core/ai/gateway.ts');
+    const tmpDir = fs.mkdtempSync(path.join(os.tmpdir(), 'gbrain-rerank-search-'));
+    try {
+      await withEnv({ GBRAIN_AUDIT_DIR: tmpDir }, async () => {
+        configureGateway({
+          reranker_model: 'zeroentropyai:zerank-2',
+          env: {},
+        });
+
+        const results = [makeResult('a', 1.0, 'doc a')];
+        const out = await applyReranker('q', results, {
+          enabled: true,
+          topNIn: 1,
+          topNOut: null,
+          model: 'zeroentropyai:zerank-2',
+        });
+
+        expect(out).toEqual(results);
+        const failures = readRecentRerankFailures(1);
+        expect(failures).toHaveLength(1);
+        expect(failures[0]!.reason).toBe('auth');
+        expect(failures[0]!.error_summary).toContain('ZEROENTROPY_API_KEY');
+      });
+    } finally {
+      fs.rmSync(tmpDir, { recursive: true, force: true });
+      configureGateway({ env: { ZEROENTROPY_API_KEY: 'test-key' } });
+    }
+  });
+
   test('fail-open on non-RerankError throw too', async () => {
     const results = [makeResult('a', 1.0, 'a')];
     const opts: RerankerOpts = {