fix(agent-hooks): no-op stale managed hook entries instead of exiting 127

A managed hook entry in ~/.claude/settings.json (and the codex/gemini/cursor
equivalents) embeds the absolute script path under that Orca install's
userData. When the script is missing — the user wiped userData, switched
dev↔prod, the previous Orca instance overwrote the path with one whose
script no longer exists, etc. — `/bin/sh "<missing>"` returns 127 and
Claude reports `PreToolUse hook (failed) error: hook exited with code 127`
on every tool call.

Wrap the POSIX launcher in `[ -x "<path>" ] && /bin/sh "<path>" || true`
so a missing/non-executable script becomes a silent exit 0. Failures
inside the script itself still propagate. The existing managed-command
matcher is substring-based on `agent-hooks/<file>`, so the next install
sweeps unguarded entries from older builds and replaces them with the
guarded form automatically.

Co-authored-by: Orca <help@stably.ai>

src/main/agent-hooks/installer-utils.test.ts

@@ -10,7 +10,12 @@ import {
 } from 'fs'
 import { tmpdir } from 'os'
 import { join } from 'path'
-import { createManagedCommandMatcher, writeHooksJson, type HooksConfig } from './installer-utils'
+import {
+  createManagedCommandMatcher,
+  wrapPosixHookCommand,
+  writeHooksJson,
+  type HooksConfig
+} from './installer-utils'
 
 let tmpDir: string
 let configPath: string
@@ -141,4 +146,31 @@ describe('createManagedCommandMatcher', () => {
   it('does not match hooks for a different agent', () => {
     expect(match('/bin/sh "/path/agent-hooks/gemini-hook.sh"')).toBe(false)
   })
+
+  it('matches the guarded launcher form so wrapped commands sweep correctly', () => {
+    // Why: wrapPosixHookCommand wraps the launcher in `[ -x ... ] && ... || true`
+    // so a stale entry no-ops instead of returning exit 127. The sweep on
+    // install() must still recognize the guarded form as managed, otherwise
+    // repeated installs would accumulate one guarded + one unguarded entry.
+    expect(
+      match(
+        '[ -x "/Users/alice/Library/Application Support/Orca/agent-hooks/claude-hook.sh" ] && /bin/sh "/Users/alice/Library/Application Support/Orca/agent-hooks/claude-hook.sh" || true'
+      )
+    ).toBe(true)
+  })
+})
+
+describe('wrapPosixHookCommand', () => {
+  it('produces a guarded command that no-ops when the script is missing', () => {
+    const cmd = wrapPosixHookCommand('/does/not/exist.sh')
+    expect(cmd).toBe('[ -x "/does/not/exist.sh" ] && /bin/sh "/does/not/exist.sh" || true')
+  })
+
+  it('preserves spaces in the script path (Library/Application Support case)', () => {
+    // Why: Electron's userData on macOS lives under "Application Support" with
+    // a space. The guard must keep the path quoted so `[ -x ]` and `/bin/sh`
+    // each see one argument.
+    const cmd = wrapPosixHookCommand('/Users/a/Library/Application Support/Orca/agent-hooks/x.sh')
+    expect(cmd).toContain('"/Users/a/Library/Application Support/Orca/agent-hooks/x.sh"')
+  })
 })

src/main/agent-hooks/installer-utils.ts

@@ -65,6 +65,18 @@ export function createManagedCommandMatcher(
   }
 }
 
+// Why: a stale managed hook entry (left over after the user wiped userData,
+// switched dev↔prod installs, or had a partial install fail) used to fire
+// `/bin/sh "<missing path>"` on every tool call, which exits 127 and surfaces
+// as `PreToolUse hook (failed) error: hook exited with code 127` in the agent
+// transcript. Wrapping the launcher in `[ -x ... ] && ... || true` makes a
+// missing/non-executable script a silent no-op so a broken install never
+// poisons the user's session. Failures inside the script itself are
+// unaffected — only the missing-script case short-circuits.
+export function wrapPosixHookCommand(scriptPath: string): string {
+  return `[ -x "${scriptPath}" ] && /bin/sh "${scriptPath}" || true`
+}
+
 export function removeManagedCommands(
   definitions: HookDefinition[],
   isManagedCommand: (command: string | undefined) => boolean

src/main/claude/hook-service.ts

@@ -6,6 +6,7 @@ import {
   createManagedCommandMatcher,
   readHooksJson,
   removeManagedCommands,
+  wrapPosixHookCommand,
   writeHooksJson,
   writeManagedScript,
   type HookDefinition
@@ -48,13 +49,16 @@ function getManagedScriptPath(): string {
 }
 
 function getManagedCommand(scriptPath: string): string {
-  // Why: on Windows, Claude Code runs hooks through Git Bash (`/usr/bin/bash`).
-  // A path with single backslashes (e.g. `C:\Users\…\claude-hook.cmd`) is
-  // interpreted by bash as a string with escape sequences, so `\U`, `\A`, etc.
-  // collapse and the launcher fails with `command not found`. Emit forward
-  // slashes — Windows accepts them in path arguments and bash leaves them
-  // intact, so the same JSON value works through every shell layer.
-  return process.platform === 'win32' ? scriptPath.replaceAll('\\', '/') : `/bin/sh "${scriptPath}"`
+  if (process.platform === 'win32') {
+    // Why: on Windows, Claude Code runs hooks through Git Bash (`/usr/bin/bash`).
+    // A path with single backslashes (e.g. `C:\Users\…\claude-hook.cmd`) is
+    // interpreted by bash as a string with escape sequences, so `\U`, `\A`, etc.
+    // collapse and the launcher fails with `command not found`. Emit forward
+    // slashes — Windows accepts them in path arguments and bash leaves them
+    // intact, so the same JSON value works through every shell layer.
+    return scriptPath.replaceAll('\\', '/')
+  }
+  return wrapPosixHookCommand(scriptPath)
 }
 
 function getManagedScript(): string {

src/main/codex/hook-service.ts

@@ -6,6 +6,7 @@ import {
   createManagedCommandMatcher,
   readHooksJson,
   removeManagedCommands,
+  wrapPosixHookCommand,
   writeHooksJson,
   writeManagedScript,
   type HookDefinition
@@ -39,7 +40,7 @@ function getManagedScriptPath(): string {
 }
 
 function getManagedCommand(scriptPath: string): string {
-  return process.platform === 'win32' ? scriptPath : `/bin/sh "${scriptPath}"`
+  return process.platform === 'win32' ? scriptPath : wrapPosixHookCommand(scriptPath)
 }
 
 function getManagedScript(): string {

src/main/cursor/hook-service.ts

@@ -6,6 +6,7 @@ import {
   createManagedCommandMatcher,
   readHooksJson,
   removeManagedCommands,
+  wrapPosixHookCommand,
   writeHooksJson,
   writeManagedScript,
   type HookDefinition
@@ -51,7 +52,7 @@ function getManagedScriptPath(): string {
 }
 
 function getManagedCommand(scriptPath: string): string {
-  return process.platform === 'win32' ? scriptPath : `/bin/sh "${scriptPath}"`
+  return process.platform === 'win32' ? scriptPath : wrapPosixHookCommand(scriptPath)
 }
 
 function getManagedScript(): string {

src/main/gemini/hook-service.ts

@@ -6,6 +6,7 @@ import {
   createManagedCommandMatcher,
   readHooksJson,
   removeManagedCommands,
+  wrapPosixHookCommand,
   writeHooksJson,
   writeManagedScript,
   type HookDefinition
@@ -37,7 +38,7 @@ function getManagedScriptPath(): string {
 }
 
 function getManagedCommand(scriptPath: string): string {
-  return process.platform === 'win32' ? scriptPath : `/bin/sh "${scriptPath}"`
+  return process.platform === 'win32' ? scriptPath : wrapPosixHookCommand(scriptPath)
 }
 
 function getManagedScript(): string {