fix(cliproxy): harden sync against edge cases

Backend:
- Handle config file deletion race condition with try-catch
- Add null check for empty config files in yaml.load()
- Limit profile names to 64 chars, require alphanumeric content
- Add 5s timeout for watcher close() to prevent hangs

Frontend:
- Add 30s fetch timeout with AbortController for sync requests

src/cliproxy/sync/auto-sync-watcher.ts

@@ -149,7 +149,15 @@ export async function stopAutoSyncWatcher(): Promise<void> {
   }
 
   if (watcherInstance) {
-    await watcherInstance.close();
+    const closePromise = watcherInstance.close();
+    const timeoutPromise = new Promise<void>((_, reject) =>
+      setTimeout(() => reject(new Error('Close timeout')), 5000)
+    );
+    try {
+      await Promise.race([closePromise, timeoutPromise]);
+    } catch (err) {
+      log(`Warning: ${(err as Error).message}, forcing cleanup`);
+    }
     watcherInstance = null;
     log('Watcher stopped');
   }

src/cliproxy/sync/local-config-sync.ts

@@ -47,7 +47,20 @@ export function syncToLocalConfig(): {
       };
     }
 
-    const configContent = fs.readFileSync(configPath, 'utf8');
+    let configContent: string;
+    try {
+      configContent = fs.readFileSync(configPath, 'utf8');
+    } catch (error) {
+      if ((error as NodeJS.ErrnoException).code === 'ENOENT') {
+        return {
+          success: false,
+          syncedCount: 0,
+          configPath,
+          error: 'CLIProxy config deleted during sync. Run ccs doctor to regenerate.',
+        };
+      }
+      throw error;
+    }
 
     // Transform payload to config format
     const claudeApiKeys = payload.map(transformToConfigFormat);
@@ -198,10 +211,12 @@ export function getLocalSyncStatus(): {
   if (fs.existsSync(configPath)) {
     try {
       const content = fs.readFileSync(configPath, 'utf8');
-      const config = yaml.load(content) as Record<string, unknown>;
-      const keys = config['claude-api-key'];
-      if (Array.isArray(keys)) {
-        currentKeyCount = keys.length;
+      const config = yaml.load(content) as Record<string, unknown> | null;
+      if (config && typeof config === 'object') {
+        const keys = config['claude-api-key'];
+        if (Array.isArray(keys)) {
+          currentKeyCount = keys.length;
+        }
       }
     } catch {
       // Ignore parse errors

src/cliproxy/sync/profile-mapper.ts

@@ -104,6 +104,17 @@ export function mapProfileToClaudeKey(profile: SyncableProfile): ClaudeKey | nul
   if (!sanitizedName || sanitizedName === '') {
     return null; // Skip profiles with invalid names
   }
+
+  // Skip if name is too long (>64 chars)
+  if (sanitizedName.length > 64) {
+    return null;
+  }
+
+  // Skip if name has no alphanumeric characters (e.g., only special chars -> "-----")
+  if (!/[a-zA-Z0-9]/.test(sanitizedName)) {
+    return null;
+  }
+
   const prefix = `${sanitizedName}-`;
 
   const claudeKey: ClaudeKey = {

ui/src/hooks/use-cliproxy-sync.ts

@@ -89,23 +89,36 @@ async function fetchSyncPreview(): Promise<SyncPreview> {
  * Execute sync to remote CLIProxy
  */
 async function executeSync(): Promise<SyncResult> {
-  const response = await fetch('/api/cliproxy/sync', {
-    method: 'POST',
-    headers: { 'Content-Type': 'application/json' },
-  });
+  const controller = new AbortController();
+  const timeoutId = setTimeout(() => controller.abort(), 30000);
 
-  if (!response.ok) {
-    let message = 'Sync failed';
-    try {
-      const data = await response.json();
-      message = data.error || data.message || message;
-    } catch {
-      // Non-JSON response (e.g., 502 Bad Gateway)
+  try {
+    const response = await fetch('/api/cliproxy/sync', {
+      method: 'POST',
+      headers: { 'Content-Type': 'application/json' },
+      signal: controller.signal,
+    });
+
+    if (!response.ok) {
+      let message = 'Sync failed';
+      try {
+        const data = await response.json();
+        message = data.error || data.message || message;
+      } catch {
+        // Non-JSON response (e.g., 502 Bad Gateway)
+      }
+      throw new Error(message);
     }
-    throw new Error(message);
-  }
 
-  return response.json();
+    return response.json();
+  } catch (error) {
+    if (error instanceof Error && error.name === 'AbortError') {
+      throw new Error('Sync request timed out after 30 seconds');
+    }
+    throw error;
+  } finally {
+    clearTimeout(timeoutId);
+  }
 }
 
 /**