fix(proxy): clean up temp launch settings

src/ccs.ts

@@ -82,7 +82,7 @@ import { tryHandleRootCommand } from './commands/root-command-router';
 // Import extracted utility functions
 import { execClaude, stripAnthropicRoutingEnv, stripBrowserEnv } from './utils/shell-executor';
 import { isDeprecatedGlmtProfileName, normalizeDeprecatedGlmtEnv } from './utils/glmt-deprecation';
-import { createOpenAICompatLaunchSettingsPath } from './utils/openai-compat-launch-settings';
+import { createOpenAICompatLaunchSettings } from './utils/openai-compat-launch-settings';
 import { maybeWarnAboutResumeLaneMismatch } from './auth/resume-lane-warning';
 import { createLogger } from './services/logging';
 import { buildCodexBrowserMcpOverrides } from './utils/browser-codex-overrides';
@@ -1460,14 +1460,14 @@ async function main(): Promise<void> {
           ),
         };
         delete proxyEnv.ANTHROPIC_API_KEY;
-        const launchSettingsPath = createOpenAICompatLaunchSettingsPath(
+        const launchSettings = createOpenAICompatLaunchSettings(
           expandedSettingsPath,
           settings
         );
 
         const launchArgs = [
           '--settings',
-          launchSettingsPath,
+          launchSettings.settingsPath,
           ...appendThirdPartyWebSearchToolArgs(browserArgs),
         ];
         const traceEnv = createWebSearchTraceContext({
@@ -1478,7 +1478,7 @@ async function main(): Promise<void> {
           settingsPath: expandedSettingsPath,
         });
 
-        execClaude(claudeCli, launchArgs, { ...proxyEnv, ...traceEnv });
+        execClaude(claudeCli, launchArgs, { ...proxyEnv, ...traceEnv }, launchSettings.cleanup);
         return;
       }
       const launchArgs = [

src/delegation/headless-executor.ts

@@ -23,7 +23,7 @@ import {
   stripAnthropicRoutingEnv,
   stripClaudeCodeEnv,
 } from '../utils/shell-executor';
-import { createOpenAICompatLaunchSettingsPath } from '../utils/openai-compat-launch-settings';
+import { createOpenAICompatLaunchSettings } from '../utils/openai-compat-launch-settings';
 import { resolveProfileContinuityInheritance } from '../auth/profile-continuity-inheritance';
 import {
   appendThirdPartyImageAnalysisToolArgs,
@@ -256,12 +256,12 @@ export class HeadlessExecutor {
     // Smart slash command detection and preservation
     const processedPrompt = this._processSlashCommand(enhancedPrompt);
 
-    const launchSettingsPath = openAICompatProfile
-      ? createOpenAICompatLaunchSettingsPath(settingsPath, settings)
-      : settingsPath;
+    const launchSettings = openAICompatProfile
+      ? createOpenAICompatLaunchSettings(settingsPath, settings)
+      : { settingsPath, cleanup: () => {} };
 
     // Prepare arguments
-    const args: string[] = ['-p', processedPrompt, '--settings', launchSettingsPath];
+    const args: string[] = ['-p', processedPrompt, '--settings', launchSettings.settingsPath];
 
     // Always use stream-json for real-time progress visibility
     args.push('--output-format', 'stream-json', '--verbose');
@@ -373,6 +373,7 @@ export class HeadlessExecutor {
       imageAnalysisEnv,
       runtimeEnvVars,
       traceEnv,
+      launchCleanup: launchSettings.cleanup,
     });
   }
 
@@ -393,6 +394,7 @@ export class HeadlessExecutor {
       imageAnalysisEnv?: Record<string, string>;
       runtimeEnvVars?: NodeJS.ProcessEnv;
       traceEnv?: Record<string, string>;
+      launchCleanup?: () => void;
     }
   ): Promise<ExecutionResult> {
     const {
@@ -406,6 +408,7 @@ export class HeadlessExecutor {
       imageAnalysisEnv = {},
       runtimeEnvVars = {},
       traceEnv = {},
+      launchCleanup = () => {},
     } = ctx;
 
     return new Promise((resolve, reject) => {
@@ -443,6 +446,14 @@ export class HeadlessExecutor {
       let progressInterval: NodeJS.Timeout | undefined;
       const messages: StreamMessage[] = [];
       let timedOut = false;
+      let cleanedUp = false;
+      const cleanupLaunchArtifacts = () => {
+        if (cleanedUp) {
+          return;
+        }
+        cleanedUp = true;
+        launchCleanup();
+      };
 
       // Setup signal handlers for cleanup
       const cleanupHandler = () => {
@@ -501,6 +512,7 @@ export class HeadlessExecutor {
 
       // Handle completion
       proc.on('close', (exitCode: number | null) => {
+        cleanupLaunchArtifacts();
         const duration = Date.now() - startTime;
 
         if (progressInterval) {
@@ -593,6 +605,7 @@ export class HeadlessExecutor {
 
       // Handle errors
       proc.on('error', (error: Error) => {
+        cleanupLaunchArtifacts();
         if (progressInterval) clearInterval(progressInterval);
         reject(new Error(`Failed to execute Claude CLI: ${error.message}`));
       });

src/utils/openai-compat-launch-settings.ts

@@ -5,10 +5,15 @@ import * as path from 'path';
 import type { Settings } from '../types/config';
 import { stripAnthropicRoutingEnv } from './shell-executor';
 
-export function createOpenAICompatLaunchSettingsPath(
+export interface OpenAICompatLaunchSettings {
+  settingsPath: string;
+  cleanup: () => void;
+}
+
+export function createOpenAICompatLaunchSettings(
   settingsPath: string,
   settings: Settings
-): string {
+): OpenAICompatLaunchSettings {
   const tempDir = fs.mkdtempSync(path.join(os.tmpdir(), 'ccs-openai-compat-settings-'));
   fs.chmodSync(tempDir, 0o700);
 
@@ -31,5 +36,17 @@ export function createOpenAICompatLaunchSettingsPath(
     mode: 0o600,
   });
 
-  return launchSettingsPath;
+  let cleanedUp = false;
+  const cleanup = (): void => {
+    if (cleanedUp) {
+      return;
+    }
+    cleanedUp = true;
+    fs.rmSync(tempDir, { recursive: true, force: true });
+  };
+
+  return {
+    settingsPath: launchSettingsPath,
+    cleanup,
+  };
 }

src/utils/shell-executor.ts

@@ -208,7 +208,8 @@ export function getWindowsEscapedCommandShell(): SpawnOptions['shell'] {
 export function execClaude(
   claudeCli: string,
   args: string[],
-  envVars: NodeJS.ProcessEnv | null = null
+  envVars: NodeJS.ProcessEnv | null = null,
+  onExitCleanup?: () => void
 ): void {
   const isWindows = process.platform === 'win32';
   const isPowerShellScript = isWindows && /\.ps1$/i.test(claudeCli);
@@ -286,6 +287,17 @@ export function execClaude(
     });
   }
 
+  let cleanedUp = false;
+  const runExitCleanup = (): void => {
+    if (cleanedUp) {
+      return;
+    }
+    cleanedUp = true;
+    onExitCleanup?.();
+  };
+  child.once('exit', runExitCleanup);
+  child.once('error', runExitCleanup);
+
   wireChildProcessSignals(child, async (err: NodeJS.ErrnoException) => {
     if (err.code === 'EACCES') {
       console.error(`[X] Claude CLI is not executable: ${claudeCli}`);

tests/unit/targets/settings-profile-browser-launch.test.ts

@@ -92,6 +92,8 @@ describe('settings profile browser launch', () => {
   let fakeClaudePath = '';
   let claudeArgsLogPath = '';
   let claudeEnvLogPath = '';
+  let claudeSettingsPathLogPath = '';
+  let claudeSettingsSnapshotPath = '';
   let browserProfileDir = '';
   let devtoolsServer: ChildProcess | undefined;
   let baseEnv: NodeJS.ProcessEnv;
@@ -107,6 +109,8 @@ describe('settings profile browser launch', () => {
     fakeClaudePath = path.join(tmpHome, 'fake-claude.sh');
     claudeArgsLogPath = path.join(tmpHome, 'claude-args.txt');
     claudeEnvLogPath = path.join(tmpHome, 'claude-env.txt');
+    claudeSettingsPathLogPath = path.join(tmpHome, 'claude-settings-path.txt');
+    claudeSettingsSnapshotPath = path.join(tmpHome, 'claude-settings-snapshot.json');
     browserProfileDir = path.join(tmpHome, 'chrome-user-data');
 
     fs.mkdirSync(ccsDir, { recursive: true });
@@ -138,6 +142,19 @@ describe('settings profile browser launch', () => {
       fakeClaudePath,
       `#!/bin/sh
 printf "%s\n" "$@" > "${claudeArgsLogPath}"
+settings_path=""
+prev=""
+for arg in "$@"; do
+  if [ "$prev" = "--settings" ]; then
+    settings_path="$arg"
+    break
+  fi
+  prev="$arg"
+done
+printf "%s" "$settings_path" > "${claudeSettingsPathLogPath}"
+if [ -n "$settings_path" ] && [ -f "$settings_path" ]; then
+  cat "$settings_path" > "${claudeSettingsSnapshotPath}"
+fi
 {
   printf "userDataDir=%s\n" "$CCS_BROWSER_USER_DATA_DIR"
   printf "legacyProfileDir=%s\n" "$CCS_BROWSER_PROFILE_DIR"
@@ -308,7 +325,7 @@ exit 0
     expect(launchSettingsPath).not.toBe(settingsPath);
 
     const persistedLaunchSettings = JSON.parse(
-      fs.readFileSync(launchSettingsPath as string, 'utf8')
+      fs.readFileSync(claudeSettingsSnapshotPath, 'utf8')
     ) as {
       env?: Record<string, string>;
       hooks?: {
@@ -333,6 +350,8 @@ exit 0
     expect(launchedEnv).not.toContain('anthropicBaseUrl=https://api.openai.com/v1');
     expect(launchedEnv).toContain('anthropicModel=gpt-5.4');
     expect(launchedEnv).toContain('maxOutputTokens=12345');
+    expect(fs.readFileSync(claudeSettingsPathLogPath, 'utf8')).toBe(launchSettingsPath);
+    expect(fs.existsSync(launchSettingsPath as string)).toBe(false);
   });
 
   it('does not auto-enable browser reuse for settings-profile launches from env overrides alone', async () => {

tests/unit/utils/claudecode-env-stripping.test.ts

@@ -31,6 +31,7 @@ const STEERING_PROMPT_SNIPPET =
   'prefer the CCS MCP tool WebSearch instead of Bash/curl/http fetches';
 const spawnCalls: SpawnCall[] = [];
 const spawnSyncCalls: SpawnSyncCall[] = [];
+const launchSettingsSnapshots: Array<{ path: string; content: string }> = [];
 const originalPlatform = process.platform;
 let baselineSigintListeners: Array<(...args: unknown[]) => void> = [];
 let baselineSigtermListeners: Array<(...args: unknown[]) => void> = [];
@@ -99,6 +100,16 @@ function registerChildProcessMock(): void {
       }
 
       spawnCalls.push({ command, args, options });
+      const settingsIndex = args.indexOf('--settings');
+      if (settingsIndex >= 0) {
+        const settingsPath = args[settingsIndex + 1];
+        if (settingsPath && fs.existsSync(settingsPath)) {
+          launchSettingsSnapshots.push({
+            path: settingsPath,
+            content: fs.readFileSync(settingsPath, 'utf8'),
+          });
+        }
+      }
 
       const child = createMockChild();
       setTimeout(() => child.emit('close', 0), 0);
@@ -193,6 +204,7 @@ describe('CLAUDECODE environment stripping', () => {
   beforeEach(() => {
     spawnCalls.length = 0;
     spawnSyncCalls.length = 0;
+    launchSettingsSnapshots.length = 0;
     process.env.CCS_QUIET = '1';
 
     // Save original env values for restoration in afterEach
@@ -695,8 +707,12 @@ describe('CLAUDECODE environment stripping', () => {
     const launchSettingsPath = args[settingsIndex + 1];
     expect(launchSettingsPath).toBeDefined();
     expect(launchSettingsPath).not.toBe(path.join(ccsDir, 'bridge.settings.json'));
+    const launchSettingsSnapshot = launchSettingsSnapshots.find(
+      (snapshot) => snapshot.path === launchSettingsPath
+    );
+    expect(launchSettingsSnapshot).toBeDefined();
 
-    const persistedLaunchSettings = JSON.parse(fs.readFileSync(launchSettingsPath, 'utf8')) as {
+    const persistedLaunchSettings = JSON.parse(launchSettingsSnapshot?.content || '{}') as {
       env?: Record<string, string>;
       hooks?: {
         PreToolUse?: Array<{
@@ -713,6 +729,7 @@ describe('CLAUDECODE environment stripping', () => {
     expect(
       persistedLaunchSettings.hooks?.PreToolUse?.[0]?.hooks?.[0]?.command
     ).toBe('echo headless-bridge-hook');
+    expect(fs.existsSync(launchSettingsPath)).toBe(false);
   });
 
   it('headless executor prepares image-analysis MCP and suppresses the legacy hook on healthy launches', async () => {