fix(desktop): keep bundle sync timeout non-fatal

apps/desktop/src/main/index.ts

@@ -2163,6 +2163,7 @@ async function bootstrap(): Promise<void> {
     configVersion: string | undefined,
     action: RuntimeCloudFetchAction
   ) => {
+    const timeoutMessage = `Project bundle sync timed out after ${Math.round(PROJECT_BUNDLE_BOOTSTRAP_TIMEOUT_MS / 1000)}s.`;
     console.info("[bundle-bootstrap]", "bundle.sync.start", {
       action,
       configVersion,
@@ -2174,7 +2175,7 @@ async function bootstrap(): Promise<void> {
       await withTimeout(
         projectBundleService.syncRemoteBundles(skills, configVersion, action),
         PROJECT_BUNDLE_BOOTSTRAP_TIMEOUT_MS,
-        `Project bundle sync timed out after ${Math.round(PROJECT_BUNDLE_BOOTSTRAP_TIMEOUT_MS / 1000)}s.`
+        timeoutMessage
       );
       console.info("[bundle-bootstrap]", "bundle.sync.done", {
         action,
@@ -2185,13 +2186,24 @@ async function bootstrap(): Promise<void> {
     } catch (error) {
       const rawMessage = error instanceof Error ? (error.stack ?? error.message) : String(error);
       const userMessage = error instanceof Error ? error.message : String(error);
-      projectBundleService.setSyncError(userMessage);
-      console.error("[bundle-bootstrap]", "bundle.sync.error", {
+      const timedOut = userMessage === timeoutMessage;
+      if (!timedOut) {
+        projectBundleService.setSyncError(userMessage);
+      }
+      const logContext = {
         action,
         configVersion,
         skillIds: skills.map((skill) => skill.skillId),
         error: rawMessage,
-        timedOut: userMessage.includes("timed out")
+        timedOut
+      };
+      if (timedOut) {
+        console.warn("[bundle-bootstrap]", "bundle.sync.timeout", logContext);
+        await traceBootstrap("project-bundle-sync:" + action + ":timeout:" + rawMessage.replace(/\r?\n/g, " | "));
+        return;
+      }
+      console.error("[bundle-bootstrap]", "bundle.sync.error", {
+        ...logContext
       });
       await traceBootstrap("project-bundle-sync:" + action + ":error:" + rawMessage.replace(/\r?\n/g, " | "));
     }

apps/desktop/src/main/ipc.ts

@@ -1170,10 +1170,13 @@ export function registerDesktopIpc(services: MainServices): RegisteredDesktopIpc
       runtimeStatus,
       gatewayStatus
     });
+    const hasUsableProjectInventory = projects.some((project) => project.ready)
+      || Boolean(currentProject?.isBuiltinHome && currentProject.ready);
     const shouldWaitForProjectSync = config.apiKeyConfigured
       && config.setupMode === "employee-key"
       && runtimeCloudStatus.state === "ready"
       && bundleSyncStatus.state === "syncing"
+      && !hasUsableProjectInventory
       && baseChatSummary.chatLaunchState !== "error";
     if (shouldWaitForProjectSync && baseChatSummary.startupPhase !== "syncing-projects") {
       void startupLogger.warn("workspace-summary", "phase.override", "Project sync phase is overriding the base startup phase because no project inventory is available yet.", {
@@ -1181,6 +1184,7 @@ export function registerDesktopIpc(services: MainServices): RegisteredDesktopIpc
         basePhase: baseChatSummary.startupPhase,
         runtimeCloudState: runtimeCloudStatus.state,
         projectCount: projects.length,
+        hasUsableProjectInventory,
         bundleSyncState: bundleSyncStatus.state
       });
     }

apps/desktop/src/main/services/project-bundle.ts

@@ -289,6 +289,15 @@ export class ProjectBundleService {
     };
   }
 
+  private setSyncFailure(error: unknown): void {
+    const message = error instanceof Error ? error.message : String(error);
+    this.syncStatus = {
+      ...this.syncStatus,
+      state: "error",
+      lastError: message
+    };
+  }
+
   async syncRemoteBundles(remoteSkills: RemoteSkillAsset[], configVersion?: string, _action?: RuntimeCloudFetchAction): Promise<void> {
     const runSync = async (): Promise<void> => {
       const startedAt = Date.now();
@@ -376,7 +385,24 @@ export class ProjectBundleService {
       });
     };
 
-    const nextRun = this.syncTail.then(runSync);
+    const nextRun = this.syncTail.then(async () => {
+      try {
+        await runSync();
+      } catch (error) {
+        this.setSyncFailure(error);
+        logBundle("bundle.sync.error", {
+          action: _action ?? "unknown",
+          configVersion,
+          error: error instanceof Error ? error.message : String(error)
+        });
+        await this.startupLogger?.error("project-bundle", "sync.error", "Project bundle sync failed.", {
+          action: _action ?? "unknown",
+          configVersion,
+          error: error instanceof Error ? (error.stack ?? error.message) : String(error)
+        });
+        throw error;
+      }
+    });
     this.syncTail = nextRun.catch(() => undefined);
     await nextRun;
   }