fix: break remaining shared/mod.js barrel imports in report generation chain (#1588)

PR #1527 fixed metrics.ts but missed several other paths that still
reach shared/mod.js → ui.js → @gsd/pi-tui during report generation
via native dynamic import() (which bypasses jiti alias resolution).

Remaining chains fixed:
- preferences.ts, preferences-validation.ts, export.ts, forensics.ts,
  migrate/parsers.ts: import from shared/format-utils.js directly
- state.ts, visualizer-data.ts, files.ts: import from milestone-ids.js
  instead of guided-flow.js (which pulls in shared/mod.js)
- files.ts: import checkExistingEnvKeys from new env-utils.ts instead
  of get-secrets-from-user.ts (which imports @gsd/pi-tui)

New file: env-utils.ts extracts the pure checkExistingEnvKeys function.

Co-authored-by: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

src/resources/extensions/env-utils.ts

@@ -0,0 +1,31 @@
+// GSD Extension — Environment variable utilities
+// Copyright (c) 2026 Jeremy McSpadden <jeremy@fluxlabs.net>
+//
+// Pure utility for checking existing env keys in .env files and process.env.
+// Extracted from get-secrets-from-user.ts to avoid pulling in @gsd/pi-tui
+// when only env-checking is needed (e.g. from files.ts during report generation).
+
+import { readFile } from "node:fs/promises";
+
+/**
+ * Check which keys already exist in a .env file or process.env.
+ * Returns the subset of `keys` that are already set.
+ */
+export async function checkExistingEnvKeys(keys: string[], envFilePath: string): Promise<string[]> {
+	let fileContent = "";
+	try {
+		fileContent = await readFile(envFilePath, "utf8");
+	} catch {
+		// ENOENT or other read error — proceed with empty content
+	}
+
+	const existing: string[] = [];
+	for (const key of keys) {
+		const escaped = key.replace(/[.*+?^${}()|[\]\\]/g, "\\$&");
+		const regex = new RegExp(`^${escaped}\\s*=`, "m");
+		if (regex.test(fileContent) || key in process.env) {
+			existing.push(key);
+		}
+	}
+	return existing;
+}

src/resources/extensions/get-secrets-from-user.ts

@@ -67,30 +67,11 @@ async function writeEnvKey(filePath: string, key: string, value: string): Promis
 
 // ─── Exported utilities ───────────────────────────────────────────────────────
 
-/**
- * Check which keys already exist in the .env file or process.env.
- * Returns the subset of `keys` that are already set.
- * Handles ENOENT gracefully (still checks process.env).
- * Empty-string values count as existing.
- */
-export async function checkExistingEnvKeys(keys: string[], envFilePath: string): Promise<string[]> {
-	let fileContent = "";
-	try {
-		fileContent = await readFile(envFilePath, "utf8");
-	} catch {
-		// ENOENT or other read error — proceed with empty content
-	}
-
-	const existing: string[] = [];
-	for (const key of keys) {
-		const escaped = key.replace(/[.*+?^${}()|[\]\\]/g, "\\$&");
-		const regex = new RegExp(`^${escaped}\\s*=`, "m");
-		if (regex.test(fileContent) || key in process.env) {
-			existing.push(key);
-		}
-	}
-	return existing;
-}
+// Re-export from env-utils.ts so existing consumers still work.
+// The implementation lives in env-utils.ts to avoid pulling @gsd/pi-tui
+// into modules that only need env-checking (e.g. files.ts during reports).
+import { checkExistingEnvKeys } from "./env-utils.js";
+export { checkExistingEnvKeys };
 
 /**
  * Detect the write destination based on project files in basePath.

src/resources/extensions/gsd/export.ts

@@ -11,7 +11,7 @@ import {
 } from "./metrics.js";
 import type { UnitMetrics } from "./metrics.js";
 import { gsdRoot } from "./paths.js";
-import { formatDuration, fileLink } from "../shared/mod.js";
+import { formatDuration, fileLink } from "../shared/format-utils.js";
 import { getErrorMessage } from "./error-utils.js";
 
 /**

src/resources/extensions/gsd/files.ts

@@ -7,7 +7,7 @@ import { promises as fs } from 'node:fs';
 import { resolve } from 'node:path';
 import { atomicWriteAsync } from './atomic-write.js';
 import { resolveMilestoneFile, relMilestoneFile, resolveGsdRootFile } from './paths.js';
-import { milestoneIdSort, findMilestoneIds } from './guided-flow.js';
+import { milestoneIdSort, findMilestoneIds } from './milestone-ids.js';
 
 import type {
   Roadmap, BoundaryMapEntry,
@@ -20,7 +20,7 @@ import type {
   ManifestStatus,
 } from './types.js';
 
-import { checkExistingEnvKeys } from '../get-secrets-from-user.js';
+import { checkExistingEnvKeys } from '../env-utils.js';
 import { parseRoadmapSlices } from './roadmap-slices.js';
 import { nativeParseRoadmap, nativeExtractSection, nativeParsePlanFile, nativeParseSummaryFile, NATIVE_UNAVAILABLE } from './native-parser-bridge.js';
 import { debugTime, debugCount } from './debug-logger.js';

src/resources/extensions/gsd/forensics.ts

@@ -27,7 +27,7 @@ import { deriveState } from "./state.js";
 import { isAutoActive } from "./auto.js";
 import { loadPrompt } from "./prompt-loader.js";
 import { gsdRoot } from "./paths.js";
-import { formatDuration } from "../shared/mod.js";
+import { formatDuration } from "../shared/format-utils.js";
 import { getAutoWorktreePath } from "./auto-worktree.js";
 
 // ─── Types ────────────────────────────────────────────────────────────────────

src/resources/extensions/gsd/migrate/parsers.ts

@@ -3,7 +3,7 @@
 // Zero Pi dependencies — uses only exported helpers from files.ts.
 
 import { splitFrontmatter, parseFrontmatterMap, extractBoldField } from '../files.js';
-import { normalizeStringArray } from '../../shared/mod.js';
+import { normalizeStringArray } from '../../shared/format-utils.js';
 
 import type {
   PlanningRoadmap,

src/resources/extensions/gsd/preferences-validation.ts

@@ -10,7 +10,7 @@ import type { GitPreferences } from "./git-service.js";
 import type { PostUnitHookConfig, PreDispatchHookConfig, TokenProfile, PhaseSkipPreferences } from "./types.js";
 import type { DynamicRoutingConfig } from "./model-router.js";
 import { VALID_BRANCH_NAME } from "./git-service.js";
-import { normalizeStringArray } from "../shared/mod.js";
+import { normalizeStringArray } from "../shared/format-utils.js";
 
 import {
   KNOWN_PREFERENCE_KEYS,

src/resources/extensions/gsd/preferences.ts

@@ -17,7 +17,7 @@ import { gsdRoot } from "./paths.js";
 import { parse as parseYaml } from "yaml";
 import type { PostUnitHookConfig, PreDispatchHookConfig, TokenProfile } from "./types.js";
 import type { DynamicRoutingConfig } from "./model-router.js";
-import { normalizeStringArray } from "../shared/mod.js";
+import { normalizeStringArray } from "../shared/format-utils.js";
 import { resolveProfileDefaults as _resolveProfileDefaults } from "./preferences-models.js";
 
 import {

src/resources/extensions/gsd/state.ts

@@ -31,7 +31,7 @@ import {
   gsdRoot,
 } from './paths.js';
 
-import { milestoneIdSort, findMilestoneIds } from './guided-flow.js';
+import { milestoneIdSort, findMilestoneIds } from './milestone-ids.js';
 import { nativeBatchParseGsdFiles, type BatchParsedFile } from './native-parser-bridge.js';
 
 import { join, resolve } from 'path';

src/resources/extensions/gsd/visualizer-data.ts

@@ -3,7 +3,7 @@
 import { existsSync, readFileSync, statSync } from 'node:fs';
 import { deriveState } from './state.js';
 import { parseRoadmap, parsePlan, parseSummary, loadFile } from './files.js';
-import { findMilestoneIds } from './guided-flow.js';
+import { findMilestoneIds } from './milestone-ids.js';
 import { resolveMilestoneFile, resolveSliceFile, resolveGsdRootFile } from './paths.js';
 import {
   getLedger,