fix(coding-agent): harden fd/rg bootstrap on windows

fixes #1348

packages/coding-agent/CHANGELOG.md

@@ -6,6 +6,7 @@
 
 - Fixed offline startup hangs by adding offline startup behavior and network timeouts during managed tool setup ([#1631](https://github.com/badlogic/pi-mono/pull/1631) by [@mcollina](https://github.com/mcollina))
 - Fixed Windows VT input initialization in ESM by loading koffi via createRequire, avoiding runtime and bundling issues in end-user environments ([#1627](https://github.com/badlogic/pi-mono/pull/1627) by [@kaste](https://github.com/kaste))
+- Fixed managed `fd`/`rg` bootstrap on Windows in Git Bash by using `extract-zip` for `.zip` archives, searching extracted layouts more robustly, and isolating extraction temp directories to avoid concurrent download races ([#1348](https://github.com/badlogic/pi-mono/issues/1348))
 
 ## [0.55.0] - 2026-02-24
 

packages/coding-agent/package.json

@@ -47,6 +47,7 @@
 		"chalk": "^5.5.0",
 		"cli-highlight": "^2.1.11",
 		"diff": "^8.0.2",
+		"extract-zip": "^2.0.1",
 		"file-type": "^21.1.1",
 		"glob": "^13.0.1",
 		"hosted-git-info": "^9.0.2",

packages/coding-agent/src/utils/tools-manager.ts

@@ -1,6 +1,7 @@
 import chalk from "chalk";
 import { spawnSync } from "child_process";
-import { chmodSync, createWriteStream, existsSync, mkdirSync, renameSync, rmSync } from "fs";
+import extractZip from "extract-zip";
+import { chmodSync, createWriteStream, existsSync, mkdirSync, readdirSync, renameSync, rmSync } from "fs";
 import { arch, platform } from "os";
 import { join } from "path";
 import { Readable } from "stream";
@@ -130,6 +131,28 @@ async function downloadFile(url: string, dest: string): Promise<void> {
 	await finished(Readable.fromWeb(response.body as any).pipe(fileStream));
 }
 
+function findBinaryRecursively(rootDir: string, binaryFileName: string): string | null {
+	const stack: string[] = [rootDir];
+
+	while (stack.length > 0) {
+		const currentDir = stack.pop();
+		if (!currentDir) continue;
+
+		const entries = readdirSync(currentDir, { withFileTypes: true });
+		for (const entry of entries) {
+			const fullPath = join(currentDir, entry.name);
+			if (entry.isFile() && entry.name === binaryFileName) {
+				return fullPath;
+			}
+			if (entry.isDirectory()) {
+				stack.push(fullPath);
+			}
+		}
+	}
+
+	return null;
+}
+
 // Download and install a tool
 async function downloadTool(tool: "fd" | "rg"): Promise<string> {
 	const config = TOOLS[tool];
@@ -158,33 +181,42 @@ async function downloadTool(tool: "fd" | "rg"): Promise<string> {
 	// Download
 	await downloadFile(downloadUrl, archivePath);
 
-	// Extract
-	const extractDir = join(TOOLS_DIR, "extract_tmp");
+	// Extract into a unique temp directory. fd and rg downloads can run concurrently
+	// during startup, so sharing a fixed directory causes races.
+	const extractDir = join(
+		TOOLS_DIR,
+		`extract_tmp_${config.binaryName}_${process.pid}_${Date.now()}_${Math.random().toString(36).slice(2, 10)}`,
+	);
 	mkdirSync(extractDir, { recursive: true });
 
 	try {
-		// Use tar for both .tar.gz and .zip extraction. Windows 10+ ships bsdtar
-		// which handles both formats, avoiding the need for `unzip` (not available
-		// on Windows by default).
-		const extractResult = assetName.endsWith(".tar.gz")
-			? spawnSync("tar", ["xzf", archivePath, "-C", extractDir], { stdio: "pipe" })
-			: assetName.endsWith(".zip")
-				? spawnSync("tar", ["xf", archivePath, "-C", extractDir], { stdio: "pipe" })
-				: null;
-
-		if (!extractResult || extractResult.error || extractResult.status !== 0) {
-			const errMsg = extractResult?.error?.message ?? extractResult?.stderr?.toString().trim() ?? "unknown error";
-			throw new Error(`Failed to extract ${assetName}: ${errMsg}`);
+		if (assetName.endsWith(".tar.gz")) {
+			const extractResult = spawnSync("tar", ["xzf", archivePath, "-C", extractDir], { stdio: "pipe" });
+			if (extractResult.error || extractResult.status !== 0) {
+				const errMsg = extractResult.error?.message ?? extractResult.stderr?.toString().trim() ?? "unknown error";
+				throw new Error(`Failed to extract ${assetName}: ${errMsg}`);
+			}
+		} else if (assetName.endsWith(".zip")) {
+			await extractZip(archivePath, { dir: extractDir });
+		} else {
+			throw new Error(`Unsupported archive format: ${assetName}`);
 		}
 
-		// Find the binary in extracted files
+		// Find the binary in extracted files. Some archives contain files directly
+		// at root, others nest under a versioned subdirectory.
+		const binaryFileName = config.binaryName + binaryExt;
 		const extractedDir = join(extractDir, assetName.replace(/\.(tar\.gz|zip)$/, ""));
-		const extractedBinary = join(extractedDir, config.binaryName + binaryExt);
+		const extractedBinaryCandidates = [join(extractedDir, binaryFileName), join(extractDir, binaryFileName)];
+		let extractedBinary = extractedBinaryCandidates.find((candidate) => existsSync(candidate));
 
-		if (existsSync(extractedBinary)) {
+		if (!extractedBinary) {
+			extractedBinary = findBinaryRecursively(extractDir, binaryFileName) ?? undefined;
+		}
+
+		if (extractedBinary) {
 			renameSync(extractedBinary, binaryPath);
 		} else {
-			throw new Error(`Binary not found in archive: ${extractedBinary}`);
+			throw new Error(`Binary not found in archive: expected ${binaryFileName} under ${extractDir}`);
 		}
 
 		// Make executable (Unix only)