From 7655a5971b346c7e9926f4f60c38929dcca2ca65 Mon Sep 17 00:00:00 2001
From: Dorian <z00york@mac.com>
Date: Sat, 18 Apr 2026 18:36:20 -0400
Subject: [PATCH] fix(ci): QEMU boot test ignores trailing numeric arg +
 enforces timeout
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The CI workflow calls `test-iso-qemu.sh "$ISO" 120`. The old arg parser
had a `case *) ISO=...` fallthrough that silently let the second
positional `120` overwrite ISO, so QEMU went looking for a file literally
named "120". That's the "failed step" the user was seeing on recent ISO
runs — the rest of the job succeeded because the QEMU step has
`continue-on-error: true`.

Changes:
- Treat `--timeout=N` or a bare numeric first-match as a CI timeout in
  seconds; the original ISO path still wins the positional.
- When a timeout is set, force `--nographic` (CI has no DISPLAY anyway)
  and wrap the QEMU invocation in coreutils' `timeout` so the script
  always returns instead of hanging.
- After termination (or timeout), grep the serial log for well-known
  systemd/live-boot markers. Pass if the kernel reached userspace, fail
  if no marker appeared within the window — useful signal rather than
  the previous "did the VM shut itself off" proxy.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
---
 image-recipe/test-iso-qemu.sh | 70 ++++++++++++++++++++++++++++++-----
 1 file changed, 60 insertions(+), 10 deletions(-)

diff --git a/image-recipe/test-iso-qemu.sh b/image-recipe/test-iso-qemu.sh
index cbe8bef3..70efe9d5 100755
--- a/image-recipe/test-iso-qemu.sh
+++ b/image-recipe/test-iso-qemu.sh
@@ -14,16 +14,31 @@ SCRIPT_DIR="$(cd "$(dirname "$0")" && pwd)"
 SERIAL_LOG="/tmp/archipelago-qemu-serial.log"
 FORCE_BIOS=false
 NOGRAPHIC=false
+TIMEOUT=0
 ISO=""
 
+# Simple arg parsing. First non-flag positional is the ISO path. A bare
+# numeric (e.g. `120`) is taken as a boot-test timeout in seconds so CI
+# can call `test-iso-qemu.sh <iso> 120` without hanging the job. The
+# pre-fix version used `case *) ISO=...`, which silently overwrote ISO
+# with the timeout value and sent QEMU looking for a file literally
+# named "120".
 for arg in "$@"; do
     case "$arg" in
         --bios) FORCE_BIOS=true ;;
         --nographic) NOGRAPHIC=true ;;
+        --timeout=*) TIMEOUT="${arg#--timeout=}" ;;
+        [0-9]*) TIMEOUT="$arg" ;;
         *) ISO="$arg" ;;
     esac
 done
 
+# A positive TIMEOUT implies headless (no DISPLAY in CI anyway) and keeps
+# the entire script wrapped in `timeout` to guarantee the job returns.
+if [ "$TIMEOUT" -gt 0 ] 2>/dev/null; then
+    NOGRAPHIC=true
+fi
+
 # Auto-detect ISO
 if [ -z "$ISO" ]; then
     ISO=$(ls -t "$SCRIPT_DIR"/results/archipelago-installer-unbundled-*.iso 2>/dev/null | head -1)
@@ -88,20 +103,55 @@ if [ "$FORCE_BIOS" = false ]; then
     fi
 fi
 
-if [ -n "$OVMF" ]; then
-    echo "  Boot: UEFI ($OVMF)"
-    qemu-system-x86_64 \
-        -machine q35 \
-        -drive if=pflash,format=raw,readonly=on,file="$OVMF" \
-        "${QEMU_ARGS[@]}"
+run_qemu() {
+    if [ -n "$OVMF" ]; then
+        echo "  Boot: UEFI ($OVMF)"
+        qemu-system-x86_64 \
+            -machine q35 \
+            -drive if=pflash,format=raw,readonly=on,file="$OVMF" \
+            "${QEMU_ARGS[@]}"
+    else
+        echo "  Boot: Legacy BIOS"
+        qemu-system-x86_64 \
+            -machine pc \
+            "${QEMU_ARGS[@]}"
+    fi
+}
+
+# Wrap the QEMU invocation in `timeout` when a CI caller passed one so
+# the script always returns instead of hanging on a VM that never exits
+# its boot loop. Exit 124 from coreutils' timeout is treated as "VM
+# reached the timeout", which for a CI boot test is success as long as
+# the serial log shows a kernel reaching userspace — we inspect that
+# after the QEMU process ends.
+if [ "$TIMEOUT" -gt 0 ] 2>/dev/null; then
+    timeout --foreground --preserve-status "${TIMEOUT}s" bash -c "$(declare -f run_qemu); run_qemu"
+    rc=$?
+    if [ $rc -eq 124 ] || [ $rc -eq 137 ]; then
+        echo "(QEMU terminated after ${TIMEOUT}s boot-test window)"
+        rc=0
+    fi
 else
-    echo "  Boot: Legacy BIOS"
-    qemu-system-x86_64 \
-        -machine pc \
-        "${QEMU_ARGS[@]}"
+    run_qemu
+    rc=$?
 fi
 
 echo ""
 echo "VM stopped. Serial log: $SERIAL_LOG"
 echo "Last 20 lines:"
 tail -20 "$SERIAL_LOG" 2>/dev/null
+
+# Boot-sanity check: the CI wrapper wants a non-zero exit only when the
+# kernel never reached userspace. Look for a well-known marker emitted
+# by live-boot/systemd early in the sequence. If the marker never
+# appeared, surface the real failure; otherwise treat "timeout reached
+# with a live kernel" as a pass.
+if [ "$TIMEOUT" -gt 0 ] 2>/dev/null && [ -f "$SERIAL_LOG" ]; then
+    if grep -qE "Welcome to Debian|Reached target|systemd\[1\]:" "$SERIAL_LOG"; then
+        echo "  Boot sanity: OK (systemd reached in serial log)"
+        exit 0
+    fi
+    echo "  Boot sanity: FAIL — no systemd markers in serial log within ${TIMEOUT}s"
+    exit 1
+fi
+exit "${rc:-0}"