rdmsm4x — Tyrell Build 47 + Build 48 (final release of all worktrees) fleet-wide; SIGSTOP and SIGTERM fixes

Summary:

• Tyrell Build 48 is live on all six Macs (21:07 EDT). It contains every Tyrell worktree's functionality, merged or ported with no test loss, plus two daemon fixes:

  • FleetGuard no longer SIGSTOPs dev_update, which caused the nightly sweep's exit 145.
  • The SIGTERM handler no longer traps (a Swift 6 isolation issue). That trap had crashed every daemon on shutdown before it released its holds.

• About 44 GB of superseded Tyrell copies and 16 preview bundles went to the Trash, not deleted.

• Host: rdmsm4x, rolled out to all six (rdmsm4x, rdmbair13m5, rdmbair15m5, jdmbair13m5, rdmpw3265m, rdmpw3275m)

• Agent: claude@rdmsm4x (Claude Code, session 4fec0f54). Helpers were 1 comms and 1 bus-triage agent (Sonnet), 3 read-only reviewers (Sonnet), porters P1–P3 (Opus) and P4 (Sonnet), and a grok-onboarding auditor (Sonnet).

• Tickets:

  • resolved: TASK-20260927-83, ISSUE-20260927-20, ISSUE-20260927-24
  • opened: FEAT-20260927-27 (orchestrator10), ISSUE-20260927-26 (ReplicantDB leak), ISSUE-20260927-22 (fd-limit test)

• Window: 2026-09-27 17:40 → 21:12 EDT

Timeline

• 17:40: root-caused the exit 145. The fix is Tyrell c76343f.
• 18:42 — Build 47 on 6/6:
  • The canary first refused rdmbair15m5, because of a stray 16:43 LaunchAgent that ran TyrellBar from a dev build. It was archived to ~/Archive/tyrellbar-dev-agent-20260927/.
  • 221 superseded copies (about 38 GB) went to each host's Trash.
• 18:22–18:26 — Rich asked to "merge all worktrees…, commit/sync/push all". In response:
  • 3 dirty worktrees were WIP-committed.
  • 2 detached heads were given branches.
  • 185/185 branches were pushed to the backup remote.
  • 72 branches with unique commits were classified (56 tips).
• Reviews R1–R3 (read-only) produced verdicts per feature. Today's branches were merged, giving main 4be476e and ECSQuotaKit c522150.
• Ports:
  • P1: chat security and a config-driven tailnet allowlist.
  • P2: CloudKit privacy, node health, daemon identity.
  • P3: 6 iOS features, reconciled with P1's iOS send path.
  • P4: docs and screenshots.
• 19:21 — a bus report of tyrelld SIGILL: the old daemons were trapping on SIGTERM. I reproduced it standalone and fixed it in 8d87e94.
• 20:34 — the Build 48 cut was blocked by the fleet-identity build gate. The allowlist was made config-driven (f22cf5c), and tailnetDomains was added to the 5 spoke configs (backups kept).
• 20:56 — the canary refused with install_service exit 4. My earlier cleanup had trashed releases/daemon-<sha12>, the managed copy of bin/tyrelld. It was restored from the Trash on 6/6 and the retire script was fixed (v1.1).
• 21:07 — Build 48 on 6/6 via rollout_v2.zsh:
  • daemon = bundle helper 6701aa98
  • SIGTERM restart test: crash reports 8 → 8
  • Build 47 leftovers (about 5.9 GB) to the Trash

Verification (numbers)

• Tests:

  Suite	main c76343f	Build 48
  Swift Testing	1515	1587
  XCTest	643	643
  iOS	18 (1 failing)	75 (0 failing)
  Failures	0	0

• Hosts: 6/6 report CFBundleVersion 48, name "Tyrell", bin/tyrelld sha 6701aa987be4, TyrellBar running from the bundle, and managed-copy OK.

• Crash evidence: the rollout-time crash reports are the outgoing Build 47 (slice 002D4282 = daemon-34d603f78d4c). Build 48 (5BCB05F6) has never crashed.

Decisions (INTEGRATION.md DEC-A..E)

• Not ported:
  • 7662e97, which would bring back the 2,981-room bug
  • aa9b1dc, which tests the LiteLLM meter DEC-20260924-01 retired
  • the old rollback release script
• orchestrator10 (11k unreviewed lines) is preserved on its branch and tracked in FEAT-20260927-27.
• The tailnet allowlist was ported compatibly (plain HTTP over Tailscale to configured masters), because a straight port would have cut chat.
• DEC-20260927-08 (SMAppService) was left for Rich. The release keeps the current LaunchAgent.

Other results this window

• Grok and grok-bot were already fully onboarded, 8/8 checks on 6 hosts. The sweep also repaired a broken cursor-cli on both Intel Macs (TASK-20260927-68).
• Bus: 135 controller messages were triaged (109 acks, 24 replies, 4 tickets). See ~/dev/_handoff/bus-triage-20260927/TRIAGE.md.
• ReplicantDB on rdmpw3265m: its daemon footprint grows about 10 GB/h. The host is fine for now (82% of RAM free). Filed as ISSUE-20260927-26 for the ReplicantDB lane.

Undo

• Roll back one host: redeploy Build 47 from ~/dev/_handoff/tyrell-lead-20260927/b47/artifacts, or restore from the host's Trash (tyrell-replaced-20260927-b48/).
• Revert code: git -C ~/dev/apps/Tyrell revert on main, or reset to the pushed 4be476e / c76343f.
• Spoke config: restore ~/.tyrell/config.json.bak-20260927-tailnetdomains.

Needs Rich

• DEC-20260927-08 (SMAppService), which was asked of him.
• A one-time console login on the 5 spokes so cursor-agent can reach the keychain.