fix(release): preserve 7za resolver failures

.github/workflows/release-cut.yml

@@ -1499,7 +1499,6 @@ jobs:
             Write-Warning 'Restored pre-rebuild installer; this release ships with unsigned inner binaries.'
           }
       # ── End Windows inner-binary signing ───────────────────────────────
-
       - name: Upload unsigned Windows installer for SignPath
         if: matrix.platform == 'win'
         id: upload-unsigned-windows-installer
@@ -1700,9 +1699,14 @@ jobs:
             # tree — 7z parses the NSIS exe directly as its embedded payload.
             # Resolve 7za via app-builder-lib; electron-builder 26.9+ dropped the
             # bundled 7zip-bin package the old hardcoded path relied on (#6487).
-            $7za = (node config/scripts/resolve-7za-path.mjs).Trim()
-            if ($LASTEXITCODE -ne 0 -or -not (Test-Path $7za)) {
-              throw "Could not resolve a 7za executable for the inner-binary evidence gate: $7za"
+            $7zaOutput = node config/scripts/resolve-7za-path.mjs
+            $7zaExitCode = $LASTEXITCODE
+            if ($7zaExitCode -ne 0) {
+              throw "The 7za resolver exited with code $7zaExitCode for the inner-binary evidence gate."
+            }
+            $7za = ($7zaOutput | Out-String).Trim()
+            if ([string]::IsNullOrWhiteSpace($7za) -or -not (Test-Path -LiteralPath $7za -PathType Leaf)) {
+              throw "The 7za resolver returned an invalid path for the inner-binary evidence gate: $7za"
             }
             New-Item -ItemType Directory -Path inner-evidence-extract -Force | Out-Null
             & $7za x 'dist/orca-windows-setup.exe' '-oinner-evidence-extract' -y | Out-Null

.github/workflows/windows-signing-rehearsal.yml

@@ -326,9 +326,14 @@ jobs:
           # Extract the signed installer and verify the files a user actually
           # gets on disk — including the exact file from issue #7785.
           # electron-builder 26.9+ removed the bundled 7zip-bin package (#6487).
-          $7za = (node config/scripts/resolve-7za-path.mjs).Trim()
-          if ($LASTEXITCODE -ne 0 -or -not (Test-Path $7za)) {
-            throw "Could not resolve a 7za executable for the signing rehearsal: $7za"
+          $7zaOutput = node config/scripts/resolve-7za-path.mjs
+          $7zaExitCode = $LASTEXITCODE
+          if ($7zaExitCode -ne 0) {
+            throw "The 7za resolver exited with code $7zaExitCode for the signing rehearsal."
+          }
+          $7za = ($7zaOutput | Out-String).Trim()
+          if ([string]::IsNullOrWhiteSpace($7za) -or -not (Test-Path -LiteralPath $7za -PathType Leaf)) {
+            throw "The 7za resolver returned an invalid path for the signing rehearsal: $7za"
           }
           New-Item -ItemType Directory -Path extracted-app -Force | Out-Null
           & $7za x 'dist/orca-windows-setup.exe' '-oextracted-app' -y | Out-Null

config/scripts/windows-signing-gate-toolset.test.mjs

@@ -75,7 +75,7 @@ function scanSpans(source) {
 
 /** `source` with the named span kinds blanked to spaces — same length, so indices still line up. */
 function blank(source, spans, kinds) {
-  const chars = [...source]
+  const chars = source.split('')
   for (const span of spans) {
     if (!kinds.includes(span.kind)) {
       continue
@@ -186,13 +186,27 @@ describe('Windows signing gates resolve 7za through the toolset resolver (#6487)
       expect(workflowSource(name)).toContain('node config/scripts/resolve-7za-path.mjs')
     })
 
-    // Why scope-checked: downgrading this `throw` to a `Write-Host` warning
-    // restores the original silent fail-open — the gate extracts nothing, finds
-    // no files, and reports success. A `toContain` on the guard condition alone
-    // does not notice.
-    it(`${name} aborts the gate when 7za cannot be resolved`, () => {
+    it(`${name} checks resolver failure before trimming its output`, () => {
       const source = workflowSource(name)
-      const guard = blockAfter(source, '$LASTEXITCODE -ne 0 -or -not (Test-Path $7za)')
+      const code = codeOf(source)
+      const resolveIndex = code.indexOf('$7zaOutput = node config/scripts/resolve-7za-path.mjs')
+      const exitCodeIndex = code.indexOf('$7zaExitCode = $LASTEXITCODE')
+      const exitGuard = blockAfter(source, 'if ($7zaExitCode -ne 0)')
+      const trimIndex = code.indexOf('$7za = ($7zaOutput | Out-String).Trim()')
+
+      expect(resolveIndex).toBeGreaterThan(-1)
+      expect(exitCodeIndex).toBeGreaterThan(resolveIndex)
+      expect(exitGuard.start).toBeGreaterThan(exitCodeIndex)
+      expect(exitGuard.code).toMatch(/\bthrow\b/)
+      expect(trimIndex).toBeGreaterThan(exitGuard.end)
+    })
+
+    it(`${name} rejects an empty or non-file 7za path`, () => {
+      const source = workflowSource(name)
+      const guard = blockAfter(
+        source,
+        'if ([string]::IsNullOrWhiteSpace($7za) -or -not (Test-Path -LiteralPath $7za -PathType Leaf))'
+      )
       expect(guard.code).toMatch(/\bthrow\b/)
     })
   }