From f9b1b3495631542c1f5fae4015afaf4a06b8768d Mon Sep 17 00:00:00 2001
From: rabbitblood <hongmingwangrabbit@gmail.com>
Date: Sun, 26 Apr 2026 08:21:18 -0700
Subject: [PATCH] =?UTF-8?q?fix(e2e):=20bump=20staging=20tenant=20TLS-readi?=
 =?UTF-8?q?ness=20timeout=203min=20=E2=86=92=2010min?=
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Closes a 4+ cycle Canvas tabs E2E flake pattern that's been blocking
staging→main PRs since 2026-04-24+ (#2096, #2094, #2055, #2079, ...).

Root cause: TLS_TIMEOUT_MS=180s (3 min) is too tight for the layered
realities of staging tenant TLS readiness:

1. Cloudflare DNS propagation through the edge (1-2 min typical)
2. Tenant CF Tunnel registering the new hostname (1-2 min)
3. CF edge ACME cert provisioning + cache (1-3 min)

Each layer can add 1-3 min on its own under heavy staging load — the
realistic worst case is well past the 3-min cap.

Provision and workspace-online timeouts were already raised to 20 min
(staging-setup.ts:42-46 history). The TLS gate was the remaining
under-budgeted step. Bumping to 10 min keeps it inside the 20-min
PROVISION envelope so a genuinely-stuck tenant still fails loud at
the earlier provision step rather than masquerading as a TLS issue.

Both call sites raised together:
- canvas/e2e/staging-setup.ts: TLS_TIMEOUT_MS = 10 * 60 * 1000
- tests/e2e/test_staging_full_saas.sh: TLS_DEADLINE += 600

Each carries an inline rationale comment so the next reviewer sees
the layer-by-layer decomposition without re-reading the issue thread.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
---
 canvas/e2e/staging-setup.ts         | 11 ++++++++++-
 tests/e2e/test_staging_full_saas.sh | 11 +++++++++--
 2 files changed, 19 insertions(+), 3 deletions(-)

diff --git a/canvas/e2e/staging-setup.ts b/canvas/e2e/staging-setup.ts
index 963f9ccb..122efdf9 100644
--- a/canvas/e2e/staging-setup.ts
+++ b/canvas/e2e/staging-setup.ts
@@ -46,7 +46,16 @@ const TENANT_DOMAIN = process.env.STAGING_TENANT_DOMAIN || "staging.moleculesai.
 // were blocking staging→main syncs on 2026-04-24.
 const PROVISION_TIMEOUT_MS = 20 * 60 * 1000;
 const WORKSPACE_ONLINE_TIMEOUT_MS = 20 * 60 * 1000;
-const TLS_TIMEOUT_MS = 3 * 60 * 1000;
+
+// TLS readiness depends on (1) Cloudflare DNS propagation through the
+// edge, (2) the tenant's CF Tunnel registering the new hostname, (3)
+// CF's edge ACME cert provisioning + cache. Each of these layers can
+// add 1-3 min on its own under heavy staging load. The original 3-min
+// cap blocked four cycles of staging→main PRs across 2026-04-24+.
+// 10 min stays inside the 20-min PROVISION_TIMEOUT envelope (so a
+// genuinely-stuck tenant still fails-loud at the provision step) but
+// absorbs the realistic worst case for a one-shot tenant TLS handshake.
+const TLS_TIMEOUT_MS = 10 * 60 * 1000;
 
 async function jsonFetch(
   url: string,
diff --git a/tests/e2e/test_staging_full_saas.sh b/tests/e2e/test_staging_full_saas.sh
index ba0fc7a9..e498ed46 100755
--- a/tests/e2e/test_staging_full_saas.sh
+++ b/tests/e2e/test_staging_full_saas.sh
@@ -195,14 +195,21 @@ TENANT_TOKEN=$(echo "$TENANT_TOKEN_RESP" | python3 -c "import json,sys; print(js
 ok "Tenant admin token retrieved (len=${#TENANT_TOKEN})"
 
 # ─── 4. Wait for tenant TLS / DNS propagation ──────────────────────────
+# 10 min — same envelope as canvas/e2e/staging-setup.ts TLS_TIMEOUT_MS.
+# CF DNS propagation + tunnel hostname registration + ACME cert + edge
+# cache routinely take 5-7 min under staging load; the original 3-min
+# cap blocked multiple staging→main PRs across 2026-04-24+. Stays
+# inside the parent provision envelope so a genuinely-stuck tenant
+# still fails loud at the earlier provision step rather than masquerading
+# as a TLS issue.
 log "4/11 Waiting for tenant TLS / DNS propagation..."
-TLS_DEADLINE=$(( $(date +%s) + 180 ))
+TLS_DEADLINE=$(( $(date +%s) + 600 ))
 while true; do
   if curl -sSfk --max-time 5 "$TENANT_URL/health" >/dev/null 2>&1; then
     break
   fi
   if [ "$(date +%s)" -gt "$TLS_DEADLINE" ]; then
-    fail "Tenant URL never responded 2xx on /health within 3 min"
+    fail "Tenant URL never responded 2xx on /health within 10 min"
   fi
   sleep 5
 done