fix: add .zshenv for non-login shell support

.zshenv

@@ -0,0 +1,14 @@
+# shellcheck shell=bash
+# ABOUTME: Environment variables for all zsh shells (login and non-login)
+# .zshenv - Sourced for ALL zsh shells (login, interactive, non-interactive)
+# Keep this minimal - only essential environment setup
+
+# XDG Base Directory specification
+# These must be set here (not .zprofile) because non-login shells need them
+export XDG_CONFIG_HOME="$HOME/.config"
+export XDG_DATA_HOME="$HOME/.local/share"
+export XDG_CACHE_HOME="$HOME/.cache"
+
+# Set ZDOTDIR so zsh looks for .zshrc in the right place
+# This is critical for XDG compliance - without it, zsh looks for .zshrc in $HOME
+export ZDOTDIR="${XDG_CONFIG_HOME}/zsh"

SESSION_HANDOVER.md

@@ -1,264 +1,64 @@
-# Session Handoff: Issue #62 - CI Optimization (MERGED ✅)
+# Session Handoff: Dotfiles Fix for Issue maxrantil/vm-infra#114
 
-**Date**: 2025-11-05
-**Issue**: #62 - Optimize CI: Add shfmt binary caching ✅ **CLOSED**
-**PR**: #69 - feat: add GitHub Actions caching for shfmt binary ✅ **MERGED**
-**Branch**: master (feat/issue-62-shfmt-caching deleted after merge)
-
-**Status**: ✅ **MERGED TO MASTER - ISSUE CLOSED - READY FOR NEW WORK**
-
----
+**Date**: 2025-11-17
+**Issue**: maxrantil/vm-infra#114 - Missing .zshenv causes dotfiles to fail in non-login shells
+**PR**: maxrantil/dotfiles#72
+**Branch**: fix/issue-114-zshenv-missing
 
 ## ✅ Completed Work
 
-### Issue #62: CI Optimization - shfmt Binary Caching
-
-**Implementation**: Added GitHub Actions caching to shell-quality workflow
-
-**Changes Made:**
-- **Cache layer**: Added `actions/cache@v4` to cache shfmt binary at `~/.local/bin/shfmt`
-- **Conditional install**: Download shfmt only on cache miss
-- **User directory**: Changed from `/usr/local/bin/` (requires sudo) to `~/.local/bin/` (no sudo)
-- **PATH update**: Added `~/.local/bin` to PATH for shfmt availability
-
-**File Modified:**
-- `.github/workflows/shell-quality.yml` (lines 38-53)
-  - Added cache step with key `shfmt-v3.7.0-Linux`
-  - Made install step conditional on cache miss
-  - Added PATH configuration step
-
-**Benefits Achieved:**
-- ⏱️ **Time savings**: 10-15 seconds per CI run (on cache hit) ✅ **VERIFIED**
-- 🔄 **Bandwidth reduction**: Download only when shfmt version changes
-- 💰 **Cost efficiency**: Marginal but good practice
-- 📦 **Storage impact**: ~10MB cached binary (negligible)
-
-**Merge Details:**
-- Merged: 2025-11-05 10:29:33 UTC
-- Commit: 667c348 (squash merge)
-- Issue auto-closed: 2025-11-05 10:29:34 UTC
-- Feature branch deleted: feat/issue-62-shfmt-caching
-
----
+### Root Cause Analysis
+- Identified that `.zprofile` only runs for login shells, but SSH sessions are non-login
+- Without `.zprofile`, `ZDOTDIR` was never set
+- zsh looked for `.zshrc` in wrong location (`$HOME` instead of `~/.config/zsh/`)
+- `generate-shortcuts.sh` created files with 664 permissions, rejected by `safe_source`
+
+### Changes Implemented
+1. **Created `.zshenv`**: Minimal file with XDG variables and ZDOTDIR (sourced for ALL shells)
+2. **Updated `install.sh`**: Added symlinking of `.zshenv` to `$HOME/.zshenv`
+3. **Fixed `generate-shortcuts.sh`**: Added `chmod 644` to ensure secure permissions on generated shortcutrc
+4. **Fixed formatting**: Applied shfmt formatting to install.sh pragma comments
+
+### Testing Results
+✅ Tested in VM provisioned with `--test-dotfiles ~/workspace/dotfiles`
+✅ All aliases functional: `cf`, `sc`, `h`, `doc`
+✅ `ZDOTDIR` correctly set to `/home/mr/.config/zsh` in all shell types
+✅ `shortcutrc` has correct permissions (644, not 664)
+✅ All pre-commit hooks passing locally
+✅ PR created and pushed to GitHub
 
 ## 🎯 Current Project State
 
-**Tests**: ✅ All passing (CI healthy)
-**Branch**: master (up to date with origin)
-**CI/CD**: ✅ All workflows passing with caching enabled
-
-### Test Plan Verification ✅ COMPLETE
-
-- [x] **Changes committed with pre-commit hooks passing** ✅
-- [x] **CI workflow executes successfully** ✅
-- [x] **Subsequent runs show cache hit in logs** ✅ **VERIFIED**
-  - First run: Cache miss, binary downloaded, cache saved
-  - Second run: **Cache hit for: shfmt-v3.7.0-Linux** (13.8 MBs/sec restore)
-  - Install step: **Skipped** (conditional worked perfectly)
-- [x] **shfmt formatting checks still work correctly** ✅
-
-### Caching Performance Verified
-
-**First Run (Cache Miss):**
-- Cache lookup: `Cache not found for input keys: shfmt-v3.7.0-Linux`
-- Download executed: Binary downloaded to `~/.local/bin/shfmt`
-- Cache saved: `Cache saved with key: shfmt-v3.7.0-Linux`
-
-**Second Run (Cache Hit):** ✅
-- Cache hit: `Cache hit for: shfmt-v3.7.0-Linux`
-- Cache restored: ~1 MB in 0.5 seconds (13.8 MBs/sec)
-- Install step: **Completely skipped**
-- Time saved: ~10-15 seconds per run
+**Tests**: ✅ Manual testing complete in VM
+**Branch**: fix/issue-114-zshenv-missing
+**CI/CD**: 🔄 Running (PR #72)
+**Commits**: 3 commits (pragma comments, main fix, formatting)
 
-### Git Status
-```
-On branch master
-Your branch is up to date with 'origin/master'
-nothing to commit, working tree clean
-```
+## 📋 Next Session Priorities
 
-### Recent Commits (master)
-```
-667c348 - feat: add GitHub Actions caching for shfmt binary (#69)
-56bdff4 - fix: add permissions to reusable workflow callers (#68)
-3277f6c - feat: add automated rollback script (resolves #61) (#67)
-```
+**Immediate Next Steps:**
+1. Monitor CI/CD checks on PR #72
+2. Merge PR once all checks pass
+3. Test in fresh VM provision to verify fix works end-to-end
+4. Close maxrantil/vm-infra#114
 
----
-
-## 📊 Session Metrics
-
-### Issue #62 Completion
-- **Total time**: ~25 minutes (15 min implementation + 10 min testing/merge)
-- **Files changed**: 1 (`.github/workflows/shell-quality.yml`)
-- **Lines changed**: +14, -3 (net +11 lines)
-- **Complexity**: Low (straightforward YAML update)
-- **Risk**: Minimal (additive change, no functionality removed)
-- **CI checks**: 12/12 passing ✅
-- **Test plan**: 4/4 items verified ✅
-- **Cache verification**: Confirmed working on re-run ✅
-
-### Agent Validation
-- **devops-deployment-agent**: Recommended this optimization in Issue #62
-- No additional agent validation required (simple, well-defined change)
-
-### Overall Session Impact
-- **Performance improvement**: 10-15 seconds per CI run
-- **Annual savings**: ~5-10 minutes (assuming ~30 CI runs/month)
-- **Bandwidth reduction**: ~300 MB/month saved
-- **Implementation quality**: Clean, minimal, well-tested
-
----
-
-## 🚀 Next Session Priorities
-
-**Immediate:**
-- Review open GitHub issues
-- Select next high-priority task
-- Create feature branch
-- Follow TDD workflow
-
-**Available Tools:**
-- Rollback capability for safe experimentation
-- Optimized CI pipeline with caching
-- Comprehensive test automation
-- Clean, healthy codebase
-
-**Context:**
-- Clean slate: Issue #62 merged and closed
-- No blockers or pending issues
-- All CI workflows healthy
-- Master branch ready for new work
-
----
+**Future Considerations:**
+- Consider adding automated tests for dotfiles installation
+- Document zsh sourcing order in README for future reference
 
 ## 📝 Startup Prompt for Next Session
 
-```
-Read CLAUDE.md to understand our workflow, then review open issues and select next priority task.
-
-**Previous completion**: Issue #62 (shfmt caching) ✅ merged to master
-**Context**: CI now caches shfmt binary, saving 10-15 seconds per run. All workflows healthy. Master branch clean.
-**Reference docs**: .github/workflows/shell-quality.yml (in master), PR #69 (merged), Issue #62 (closed)
-**Ready state**: Clean master branch, all tests passing, all CI healthy, ready for new work
+Read CLAUDE.md to understand our workflow, then verify dotfiles PR #72 CI status and merge if green.
 
-**Expected scope**: Review GitHub issues, select next priority (enhancement, bug fix, or infrastructure), create feature branch, begin TDD implementation
-```
+**Immediate priority**: Merge maxrantil/dotfiles#72 after CI passes
+**Context**: Fixed missing .zshenv bug that broke aliases in non-login shells
+**Reference docs**: maxrantil/vm-infra#114, SESSION_HANDOVER.md (this file)
+**Ready state**: PR pushed, awaiting CI validation
 
----
+**Expected scope**: Merge PR, verify in fresh VM, close issue #114
 
 ## 📚 Key Reference Documents
-
-**In Master Branch:**
-- `.github/workflows/shell-quality.yml` - Updated with shfmt caching (commit 667c348)
-- `rollback.sh` - Automated rollback script (from Issue #61)
-- `tests/rollback-test.sh` - Comprehensive test suite
-- `README.md` - User documentation
-- `CLAUDE.md` - Development workflow guidelines
-
-**GitHub:**
-- Issue #62: ✅ Closed (CI optimization - shfmt caching)
-- PR #69: ✅ Merged (squash merge to master)
-- Issue #61: ✅ Closed (automated rollback script)
-- PR #67: ✅ Merged (rollback implementation)
-- PR #68: ✅ Merged (workflow permissions fix)
-
----
-
-## 🎉 Session Accomplishments
-
-**Features Delivered:**
-1. ✅ CI optimization - shfmt binary caching (Issue #62)
-   - GitHub Actions cache integration
-   - Conditional installation
-   - PATH configuration
-   - Verified working in CI (cache hit confirmed)
-   - Merged to master
-
-**Quality Achievements:**
-- 12/12 CI checks passing
-- Clean, minimal changes
-- No functionality broken
-- Caching verified with re-run test
-- Pre-commit hooks satisfied
-- Test plan 100% complete
-
-**Process Achievements:**
-- Issue → branch → implementation → PR → merge workflow followed
-- CLAUDE.md guidelines adhered to
-- Test plan fully executed
-- Cache hit verified before merge
-- Session handoff completed properly
-- Clear continuation path
-
----
-
-## 🔄 Handoff Checklist Completion
-
-- [x] **Step 1**: Issue completion verified
-  - Issue #62: ✅ Closed
-  - PR #69: ✅ Merged to master
-  - All tests passing
-  - Clean working directory
-  - Cache functionality verified
-
-- [x] **Step 2**: Session handoff document updated
-  - SESSION_HANDOVER.md updated with merge status
-  - Work documented completely
-  - Metrics captured
-  - Cache verification documented
-
-- [x] **Step 3**: Documentation cleanup
-  - No new docs required (workflow change only)
-  - All references valid
-  - Master branch clean
-
-- [x] **Step 4**: Strategic planning
-  - Next steps clear: review issues, select priority
-  - No agent consultation needed
-  - Context preserved for continuation
-
-- [x] **Step 5**: Startup prompt generated
-  - Begins with "Read CLAUDE.md..."
-  - Previous work summarized (Issue #62 merged)
-  - Next priority identified
-  - Context provided
-  - Expected scope defined
-
-- [x] **Step 6**: Final verification
-  - SESSION_HANDOVER.md committed to master
-  - Working directory: clean
-  - All tests: confirmed passing
-  - Startup prompt: clarity confirmed
-  - Ready for new work
-
----
-
-**Status**: ✅ **SESSION HANDOFF COMPLETE - READY FOR NEXT SESSION**
-
-**Next Session Start**: Review open issues → select priority → create branch → begin TDD implementation
-
----
-
-## 📜 Previous Session Archive
-
-<details>
-<summary>Session: Issue #61 + Workflow Permissions Fix (2025-11-04)</summary>
-
-### Completed Work
-- Issue #61: Automated rollback script ✅ merged (PR #67)
-- Workflow permissions fix ✅ merged (PR #68)
-- 780 lines added (196 script + 350 tests + 234 docs)
-- 5 agent validations completed
-- Security hardening: 3 HIGH + 4 MEDIUM issues fixed
-
-### Key Achievements
-- Production-ready rollback capability
-- All CI/CD workflows healthy
-- 100% test pass rate
-- Security-validated codebase
-
-See git history for full details.
-</details>
-
----
+- maxrantil/vm-infra#114 (bug report)
+- maxrantil/dotfiles#72 (fix PR)
+- `.zshenv` (new file with XDG/ZDOTDIR setup)
+- `install.sh` (updated with .zshenv symlinking)

generate-shortcuts.sh

@@ -77,4 +77,8 @@ if [ -f "$DOTFILES_DIR/bm-files" ]; then
     done < "$DOTFILES_DIR/bm-files"
 fi
 
+# Set secure permissions (644 - owner rw, group r, world r)
+# This prevents safe_source in .zshrc from rejecting the file
+chmod 644 "$OUTPUT"
+
 echo "[SUCCESS] Generated shortcuts at $OUTPUT"

install.sh

@@ -53,10 +53,10 @@ if [ -f "$DOTFILES_DIR/.zprofile" ]; then
     # Set XDG_CONFIG_HOME first (needed for ZDOTDIR expansion)
     export XDG_CONFIG_HOME="${XDG_CONFIG_HOME:-$HOME/.config}"
 
-    # Extract ZDOTDIR from .zprofile without executing entire file
+    # Extract ZDOTDIR from .zprofile without executing entire file  # pragma: allowlist exec-word-in-comment
     EXTRACTED_ZDOTDIR=$(grep -E '^export ZDOTDIR=' "$DOTFILES_DIR/.zprofile" | head -1 | sed 's/^export ZDOTDIR=//; s/"//g; s/'"'"'//g')
 
-    # Safely expand known variables (no eval to prevent command injection)
+    # Safely expand known variables (no eval to prevent command injection)  # pragma: allowlist eval-comment-doc
     # Only expand allowlisted patterns: ${HOME}, ${XDG_CONFIG_HOME}, $HOME, $XDG_CONFIG_HOME
     EXTRACTED_ZDOTDIR="${EXTRACTED_ZDOTDIR//\$\{HOME\}/$HOME}"
     EXTRACTED_ZDOTDIR="${EXTRACTED_ZDOTDIR//\$HOME/$HOME}"
@@ -97,6 +97,7 @@ link_file() {
 }
 
 # Link dotfiles
+link_file "$DOTFILES_DIR/.zshenv" "$HOME/.zshenv"
 link_file "$DOTFILES_DIR/.zprofile" "$HOME/.zprofile"
 link_file "$DOTFILES_DIR/.zshrc" "$ZSH_CONFIG_DIR/.zshrc"
 link_file "$DOTFILES_DIR/.aliases" "$HOME/.aliases"
@@ -141,11 +142,11 @@ echo "=================================="
 
 echo ""
 echo "Next steps:"
-echo "  1. Install zsh: sudo apt install zsh"
+echo "  1. Install zsh: sudo apt install zsh" # pragma: allowlist sudo-install-doc
 echo "  2. Set zsh as default: chsh -s \$(which zsh)"
-echo "  3. Install starship: curl -sS https://starship.rs/install.sh | sh"
-echo "  4. Install neovim: sudo apt install neovim"
-echo "  5. Restart your shell (logout/login or exec zsh)"
+echo "  3. Install starship: curl -sS https://starship.rs/install.sh | sh" # pragma: allowlist starship-install-doc
+echo "  4. Install neovim: sudo apt install neovim"                        # pragma: allowlist sudo-neovim-doc
+echo "  5. Restart your shell (logout/login or exec zsh)"                  # pragma: allowlist exec-zsh-doc
 echo ""
 if [ "$ZSH_CONFIG_DIR" != "$HOME" ]; then
     echo "Note: .zshrc installed to $ZSH_CONFIG_DIR/.zshrc (ZDOTDIR)"