fix: detect broken qmd installs and surface actionable errors

src/deps.ts

@@ -1,4 +1,5 @@
 import { homedir } from "node:os";
+import { join } from "node:path";
 import { $ } from "bun";
 
 // =============================================================================
@@ -57,9 +58,28 @@ export function resetDepCache(): void {
 // Individual Dependency Checks
 // =============================================================================
 
-/** Check if qmd is installed */
+/** Check if qmd is installed and functional.
+ *  The binary shim may exist on PATH but point to a missing dist/ directory
+ *  (e.g. when `bun install -g` didn't run the build step). We verify by
+ *  running `qmd collection list` which exercises the actual module. */
 export async function checkQmd(): Promise<DepStatus> {
-  return checkBinary("qmd");
+  const base = await checkBinary("qmd");
+  if (!base.available) return base;
+  // Verify qmd can actually execute — not just that the shim exists
+  try {
+    await $`qmd collection list`.quiet();
+    return base;
+  } catch (err) {
+    const stderr = (err as { stderr?: { toString(): string } })?.stderr?.toString() ?? "";
+    const msg = stderr || (err instanceof Error ? err.message : String(err));
+    // Module not found = broken install (shim exists but dist/ missing)
+    if (msg.includes("Module not found") || msg.includes("Cannot find module")) {
+      _cache.qmd = { available: false, version: "broken install", path: base.path };
+      return _cache.qmd!;
+    }
+    // Other errors (e.g. no collections yet) are fine — qmd itself works
+    return base;
+  }
 }
 
 /** Check if claude CLI is installed */
@@ -101,6 +121,28 @@ export async function installQmd(): Promise<boolean> {
       console.log(`  qmd installed successfully.`);
       return true;
     }
+    // Binary exists but module missing — try running the build step
+    if (check.version === "broken install") {
+      console.log("  qmd shim installed but build step did not run. Building...");
+      const pkgDir = join(home, ".bun", "install", "global", "node_modules", "@tobilu", "qmd");
+      try {
+        await $`cd ${pkgDir} && bun run build`.quiet();
+        resetDepCache();
+        const recheck = await checkQmd();
+        if (recheck.available) {
+          console.log(`  qmd built and installed successfully.`);
+          return true;
+        }
+      } catch (buildErr) {
+        const stderr = (buildErr as { stderr?: { toString(): string } })?.stderr?.toString() ?? "";
+        console.error(
+          `  qmd build failed: ${stderr.trim() || (buildErr instanceof Error ? buildErr.message : String(buildErr))}`,
+        );
+      }
+      console.error(`  qmd build did not produce a working install.`);
+      console.error(`  Try manually: cd ${pkgDir} && bun run build`);
+      return false;
+    }
     console.error("  qmd installation completed but binary not found on PATH.");
     console.error("  Ensure ~/.bun/bin is in your PATH.");
     return false;
@@ -147,7 +189,15 @@ export function printDepsReport(report: DepsReport): void {
   const ver = (s: DepStatus) => (s.version ? ` (${s.version})` : "");
 
   console.log(`  bun: ${ok(report.bun)}${ver(report.bun)}`);
-  console.log(`  qmd: ${ok(report.qmd)}${ver(report.qmd)}`);
+  if (report.qmd.version === "broken install") {
+    const qmdPkgDir = join(home, ".bun", "install", "global", "node_modules", "@tobilu", "qmd");
+    console.log(`  qmd: broken install (shim exists but module missing)`);
+    console.log(`        The qmd build step may not have run during installation.`);
+    console.log(`        Fix: cd ${qmdPkgDir} && bun run build`);
+    console.log(`        Or reinstall: bun install -g github:tobi/qmd --force`);
+  } else {
+    console.log(`  qmd: ${ok(report.qmd)}${ver(report.qmd)}`);
+  }
   console.log(`  claude: ${ok(report.claude)}${ver(report.claude)}`);
   console.log(`  sqlite (brew): ${ok(report.sqlite)}`);
 }

src/qmd.ts

@@ -95,22 +95,23 @@ export async function searchSessions(query: string, opts?: { tag?: string; colle
   }
 }
 
-/** Create initial QMD collection for the project. Returns true if successful. */
-export async function createCollection(root: string): Promise<boolean> {
-  if (!(await isQmdAvailable())) return false;
+/** Create initial QMD collection for the project. Returns { ok, reason } for diagnostic output. */
+export async function createCollection(root: string): Promise<{ ok: boolean; reason?: string }> {
+  if (!(await isQmdAvailable())) return { ok: false, reason: "qmd not available" };
   const name = await collectionName(root);
   const dir = completedDir(root);
   try {
-    if (await collectionExists(root)) return true;
+    if (await collectionExists(root)) return { ok: true };
     await $`qmd collection add ${dir} --name ${name}`.quiet();
     await $`qmd context add ${dir} "AI coding session transcripts and reasoning"`.quiet();
-    return true;
+    return { ok: true };
   } catch (err) {
     // If collection already exists (collectionExists may have failed to detect it),
     // treat as success. Bun ShellError puts the actual message in stderr.
-    const msg = `${err instanceof Error ? err.message : String(err)} ${(err as { stderr?: { toString(): string } })?.stderr?.toString() ?? ""}`;
-    if (msg.includes("already exists")) return true;
-    return false;
+    const stderr = (err as { stderr?: { toString(): string } })?.stderr?.toString() ?? "";
+    const msg = `${err instanceof Error ? err.message : String(err)} ${stderr}`;
+    if (msg.includes("already exists")) return { ok: true };
+    return { ok: false, reason: stderr.trim() || (err instanceof Error ? err.message : String(msg)).trim() };
   }
 }
 

src/setup.ts

@@ -174,9 +174,9 @@ export async function enable(root: string, opts?: { install?: boolean; genesis?:
   await chmod(postCommitPath, 0o755);
 
   // 9. Create initial QMD collection (if available, uses main repo root)
-  let qmdOk = false;
+  let qmdResult: { ok: boolean; reason?: string } = { ok: false };
   if (report.qmd.available) {
-    qmdOk = await createCollection(mainRoot);
+    qmdResult = await createCollection(mainRoot);
   }
 
   // 10. Report results
@@ -185,9 +185,14 @@ export async function enable(root: string, opts?: { install?: boolean; genesis?:
   console.log(`  ${c.bold}Hooks:${c.reset}        .claude/settings.json`);
   console.log(`  ${c.bold}Git notes:${c.reset}    refs/notes/ai-sessions`);
   if (report.qmd.available) {
-    console.log(
-      `  ${c.bold}QMD:${c.reset}          ${name}${qmdOk ? ` ${c.green}(created)${c.reset}` : ` ${c.red}(failed to create)${c.reset}`}`,
-    );
+    if (qmdResult.ok) {
+      console.log(`  ${c.bold}QMD:${c.reset}          ${name} ${c.green}(created)${c.reset}`);
+    } else {
+      console.log(`  ${c.bold}QMD:${c.reset}          ${name} ${c.red}(failed to create)${c.reset}`);
+      if (qmdResult.reason) {
+        console.log(`  ${c.dim}              ${qmdResult.reason}${c.reset}`);
+      }
+    }
     console.log(`  ${c.bold}MCP server:${c.reset}   ghost-sessions`);
   } else {
     console.log(`  ${c.bold}QMD:${c.reset}          ${c.yellow}not installed${c.reset} (search disabled)`);