Enhance NSIS installer script with size validation and staging checks

- Added a new parameter for minimum installer size to ensure the generated NSIS installer meets the required threshold.
- Implemented a function to calculate the total size of staged application files, validating that the complete app bundle is present before proceeding with the installer creation.
- Improved error handling to provide clearer messages if the staged application or installer does not meet size requirements.

scripts/build-windows-nsis.ps1

@@ -6,7 +6,9 @@ param(
   [string]$OutputExe,
 
   [Parameter(Mandatory = $true)]
-  [string]$Version
+  [string]$Version,
+
+  [long]$MinInstallerBytes = 10485760
 )
 
 $ErrorActionPreference = "Stop"
@@ -31,6 +33,16 @@ function Find-Makensis() {
   throw "Could not find makensis. Install NSIS 3.x on the Windows build agent."
 }
 
+function Get-DirectoryBytes {
+  param([string]$Path)
+
+  $total = 0
+  foreach ($item in Get-ChildItem -LiteralPath $Path -Recurse -File -Force) {
+    $total += $item.Length
+  }
+  return $total
+}
+
 $rootDir = Split-Path -Parent $PSScriptRoot
 $nsiPath = Join-Path $rootDir "packaging/windows/farmcontrol-server.nsi"
 $installerInclude = Join-Path $rootDir "packaging/windows/installer.nsh"
@@ -42,6 +54,22 @@ if (Test-Path $workDir) {
 New-Item -ItemType Directory -Path $workDir | Out-Null
 
 $appDirPath = (Resolve-Path -LiteralPath $AppDir).Path
+$stagingAppDir = Join-Path $workDir "app"
+
+Write-Host "Staging application files for NSIS from $appDirPath"
+Copy-Item -LiteralPath $appDirPath -Destination $stagingAppDir -Recurse -Force
+
+$stagedAppBytes = Get-DirectoryBytes $stagingAppDir
+Write-Host "Staged application size: $([math]::Round($stagedAppBytes / 1MB, 2)) MB"
+
+if ($stagedAppBytes -lt 5242880) {
+  throw "Staged application is only $([math]::Round($stagedAppBytes / 1KB, 1)) KiB. Expected a full Electrobun app bundle before building the installer."
+}
+
+$requiredExe = Join-Path $stagingAppDir "bin\farmcontrol-server.exe"
+if (-not (Test-Path $requiredExe)) {
+  throw "Staged application is missing bin\farmcontrol-server.exe"
+}
 
 Copy-Item -LiteralPath $nsiPath -Destination (Join-Path $workDir "farmcontrol-server.nsi")
 Copy-Item -LiteralPath $installerInclude -Destination (Join-Path $workDir "installer.nsh")
@@ -58,11 +86,12 @@ $makensisArgs = @(
   "/NOCD"
   "/DOUTFILE=$outputExePath"
   "/DVERSION=$Version"
-  "/DAPP_SOURCE_DIR=$appDirPath"
+  "/DAPP_SOURCE_DIR=app"
 )
 
 if (Test-Path $iconPath) {
-  $makensisArgs += "/DINSTALLER_ICON=$iconPath"
+  $iconPathForNsis = $iconPath.Replace("\", "/")
+  $makensisArgs += "/DINSTALLER_ICON=$iconPathForNsis"
 }
 
 $makensisArgs += (Join-Path $workDir "farmcontrol-server.nsi")
@@ -70,6 +99,9 @@ $makensisArgs += (Join-Path $workDir "farmcontrol-server.nsi")
 Push-Location $workDir
 try {
   & $makensis @makensisArgs
+  if ($LASTEXITCODE -ne 0) {
+    throw "makensis failed with exit code $LASTEXITCODE"
+  }
 } finally {
   Pop-Location
 }
@@ -78,6 +110,13 @@ if (-not (Test-Path $outputExePath)) {
   throw "NSIS installer was not created at $outputExePath"
 }
 
+$installerBytes = (Get-Item -LiteralPath $outputExePath).Length
+Write-Host "NSIS installer size: $([math]::Round($installerBytes / 1MB, 2)) MB"
+
+if ($installerBytes -lt $MinInstallerBytes) {
+  throw "NSIS installer is only $([math]::Round($installerBytes / 1KB, 1)) KiB at $outputExePath. The application files were not packaged. Check APP_SOURCE_DIR staging and NSIS logs."
+}
+
 if (Test-Path $iconPath) {
   $embedIconScript = Join-Path $rootDir "scripts/embed-windows-exe-icon.mjs"
   & bun $embedIconScript $outputExePath --icon $iconPath

scripts/finalize-desktop-artifacts.mjs

@@ -480,6 +480,14 @@ function buildWindowsNsis(appDir, arch) {
     );
   }
 
+  const minInstallerBytes = 10 * 1024 * 1024;
+  const installerSize = statSync(exePath).size;
+  if (installerSize < minInstallerBytes) {
+    throw new Error(
+      `Windows installer ${path.basename(exePath)} is only ${(installerSize / 1024).toFixed(1)} KiB; expected at least ${minInstallerBytes / (1024 * 1024)} MiB`,
+    );
+  }
+
   console.log(`Published ${exePath}`);
   return exePath;
 }