fix(startup): Windows never crashes resolving userData when roaming AppData is unavailable (#25113)

* fix(startup): pin Windows appData and userData before anything resolves them

A Windows session without a loaded profile (e.g. orca serve over SSH) can fail the
roaming AppData known-folder lookup. Electron 43 then falls through to Chromium's
userData provider and crashes natively. Resolve appData first (falling back to
APPDATA, then USERPROFILE\AppData\Roaming), and set userData explicitly so
Electron's provider never runs.

* test(startup): remove the AppData fixture through the retrying helper

---------

Co-authored-by: m4air <m4air@Mac.localdomain>

.github/workflows/e2e.yml

@@ -342,7 +342,8 @@ jobs:
               . != "tests/e2e/ssh-localhost.spec.ts" and
               . != "tests/e2e/terminal-ibus-hangul-native.spec.ts" and
               . != "tests/e2e/orcad-serve-mode-switch.spec.ts" and
-              . != "tests/e2e/ssh-orcad-auto-convert.spec.ts"
+              . != "tests/e2e/ssh-orcad-auto-convert.spec.ts" and
+              . != "tests/e2e/windows-missing-appdata-startup.spec.ts"
             )' <<<"$TEST_FILES_JSON" > "$RUNNER_TEMP/general-e2e-specs"
           fi
           mapfile -t TEST_FILES < "$RUNNER_TEMP/general-e2e-specs"
@@ -552,6 +553,44 @@ jobs:
           retention-days: 7
           if-no-files-found: ignore
 
+  # A profile-less Windows session has no roaming AppData; Electron 43 used to crash natively there.
+  windows-missing-appdata-startup:
+    name: orca serve starts without AppData on Windows
+    if: inputs.test_files == '' || contains(inputs.test_files, 'tests/e2e/windows-missing-appdata-startup.spec.ts')
+    runs-on: windows-2022
+    timeout-minutes: 30
+    env:
+      NODE_OPTIONS: --max-old-space-size=4096
+      ORCA_BACKGROUND_LAUNCH: '1'
+    steps:
+      - uses: actions/checkout@v6
+        with:
+          ref: ${{ inputs.ref || github.ref }}
+          persist-credentials: false
+      - uses: ./.github/actions/install-node-dependencies
+        with:
+          native-runtime: electron
+      - name: Build the e2e app and CLI
+        shell: bash
+        run: |
+          pnpm exec electron-vite build --mode e2e
+          pnpm run build:cli
+      - name: Start serve with no AppData folder
+        env:
+          SKIP_BUILD: '1'
+          ORCA_E2E_FORWARD_APP_LOGS: '1'
+          ORCA_STARTUP_DIAGNOSTICS: '1'
+          ELECTRON_ENABLE_LOGGING: '1'
+          ELECTRON_ENABLE_STACK_DUMPING: '1'
+        run: pnpm exec playwright test --config tests/playwright.config.ts tests/e2e/windows-missing-appdata-startup.spec.ts --project=electron-headless --workers=1
+      - uses: actions/upload-artifact@v7
+        if: failure()
+        with:
+          name: windows-missing-appdata-startup-traces
+          path: test-results/
+          retention-days: 7
+          if-no-files-found: ignore
+
   # #24979 on a real host: a relay-era Docker host converts to managed orcad on connect. Needs the
   # orcad template for the fixture's target (Debian, linux-x64-glibc), which only this job builds.
   orcad-auto-convert-docker:

.github/workflows/pr.yml

@@ -1154,6 +1154,7 @@ jobs:
           src/main/cursor/hook-service.test.ts
           src/main/orca-profiles/profile-index-store.test.ts
           src/main/startup/windows-install-dir-acl-repair.win32.test.ts
+          src/main/startup/windows-app-data-path.test.ts
           src/main/runtime/repo-worktree-admin-fingerprint.test.ts
           src/main/runtime/worktree-scan-admin-fingerprint-gate.test.ts
           src/shared/secure-file-fsync-flags.test.ts