fix: use PowerShell Start-Process for Windows browser launch, prevent URL wrapping (#1870)

Closes #1574

packages/pi-coding-agent/src/modes/interactive/components/login-dialog.ts

@@ -1,7 +1,7 @@
 // GSD Login Dialog Component — OAuth login flow UI
 // Copyright (c) 2026 Jeremy McSpadden <jeremy@fluxlabs.net>
 import { getOAuthProviders } from "@gsd/pi-ai/oauth";
-import { Container, type Focusable, getEditorKeybindings, Input, Spacer, Text, type TUI } from "@gsd/pi-tui";
+import { Container, type Focusable, getEditorKeybindings, Input, Spacer, Text, truncateToWidth, type TUI } from "@gsd/pi-tui";
 import { execFile } from "child_process";
 import { theme } from "../theme/theme.js";
 import { DynamicBorder } from "./dynamic-border.js";
@@ -121,21 +121,25 @@ export class LoginDialogComponent extends Container implements Focusable {
 	showAuth(url: string, instructions?: string): void {
 		this.contentContainer.clear();
 		this.contentContainer.addChild(new Spacer(1));
-		this.contentContainer.addChild(new Text(theme.fg("accent", url), 1, 0));
+
+		// Truncate the visible URL text so it never wraps (which would break
+		// the OSC 8 hyperlink). The full URL is still the link target.
+		const maxUrlWidth = Math.max(20, this.tui.terminal.columns - 4);
+		const displayUrl = truncateToWidth(url, maxUrlWidth);
+		const urlLink = `\x1b]8;;${url}\x07${theme.fg("accent", displayUrl)}\x1b]8;;\x07`;
+		this.contentContainer.addChild(new Text(urlLink, 1, 0));
 
 		const clickHint = process.platform === "darwin" ? "Cmd+click to open" : "Ctrl+click to open";
-		const hyperlink = `\x1b]8;;${url}\x07${clickHint}\x1b]8;;\x07`;
-		this.contentContainer.addChild(new Text(theme.fg("dim", hyperlink), 1, 0));
+		this.contentContainer.addChild(new Text(theme.fg("dim", clickHint), 1, 0));
 
 		if (instructions) {
 			this.contentContainer.addChild(new Spacer(1));
 			this.contentContainer.addChild(new Text(theme.fg("warning", instructions), 1, 0));
 		}
 
-		// Try to open browser — on Windows, `start` needs an empty title arg
-		// so it treats the URL as a target, not a window title
+		// PowerShell's Start-Process handles URLs with '&' safely; cmd /c start does not.
 		if (process.platform === "win32") {
-			execFile("cmd", ["/c", "start", "", url], () => {});
+			execFile("powershell", ["-c", `Start-Process '${url.replace(/'/g, "''")}'`], () => {});
 		} else {
 			const openCmd = process.platform === "darwin" ? "open" : "xdg-open";
 			execFile(openCmd, [url], () => {});

src/onboarding.ts

@@ -124,7 +124,8 @@ async function loadPico(): Promise<PicoModule> {
 /** Open a URL in the system browser (best-effort, non-blocking) */
 function openBrowser(url: string): void {
   if (process.platform === 'win32') {
-    execFile('cmd', ['/c', 'start', '', url], () => {})
+    // PowerShell's Start-Process handles URLs with '&' safely; cmd /c start does not.
+    execFile('powershell', ['-c', `Start-Process '${url.replace(/'/g, "''")}'`], () => {})
   } else {
     const cmd = process.platform === 'darwin' ? 'open' : 'xdg-open'
     execFile(cmd, [url], () => {})

src/resources/extensions/gsd/export.ts

@@ -4,7 +4,7 @@
 import type { ExtensionCommandContext } from "@gsd/pi-coding-agent";
 import { writeFileSync, mkdirSync } from "node:fs";
 import { join, basename } from "node:path";
-import { exec } from "node:child_process";
+import { exec, execFile } from "node:child_process";
 import {
   getLedger, getProjectTotals, aggregateByPhase, aggregateBySlice,
   aggregateByModel, formatCost, formatTokenCount, loadLedgerFromDisk,
@@ -20,20 +20,13 @@ import { getErrorMessage } from "./error-utils.js";
  * Non-blocking, non-fatal — failures are silently ignored.
  */
 export function openInBrowser(filePath: string): void {
-  const cmd =
-    process.platform === "darwin" ? "open" :
-    process.platform === "win32" ? "start" :
-    "xdg-open";
-
-  // On Windows, `start` needs an empty title argument when the path has spaces
-  const args = process.platform === "win32"
-    ? `"" "${filePath}"`
-    : `"${filePath}"`;
-
-  exec(`${cmd} ${args}`, (err) => {
-    // Non-fatal — if the browser can't be opened, the file path is still shown
-    if (err) void err;
-  });
+  if (process.platform === "win32") {
+    // PowerShell's Start-Process handles paths with '&' and spaces safely.
+    execFile("powershell", ["-c", `Start-Process '${filePath.replace(/'/g, "''")}'`], () => {});
+  } else {
+    const cmd = process.platform === "darwin" ? "open" : "xdg-open";
+    execFile(cmd, [filePath], () => {});
+  }
 }
 
 /**

src/web-mode.ts

@@ -1,5 +1,5 @@
 import { randomBytes } from 'node:crypto'
-import { exec, spawn, type ChildProcess, type SpawnOptions } from 'node:child_process'
+import { exec, execFile, spawn, type ChildProcess, type SpawnOptions } from 'node:child_process'
 import { existsSync, readFileSync, unlinkSync, writeFileSync } from 'node:fs'
 import { request as httpRequest } from 'node:http'
 import { createServer } from 'node:net'
@@ -12,12 +12,13 @@ const DEFAULT_PACKAGE_ROOT = resolve(dirname(fileURLToPath(import.meta.url)), '.
 
 /** Open a URL in the user's default browser. */
 function openBrowser(url: string): void {
-  const cmd = process.platform === 'darwin' ? 'open' :
-    process.platform === 'win32' ? 'start' :
-      'xdg-open'
-  exec(`${cmd} "${url}"`, () => {
-    // Ignore errors — user can manually open the URL
-  })
+  if (process.platform === 'win32') {
+    // PowerShell's Start-Process handles URLs with '&' safely; cmd /c start does not.
+    execFile('powershell', ['-c', `Start-Process '${url.replace(/'/g, "''")}'`], () => {})
+  } else {
+    const cmd = process.platform === 'darwin' ? 'open' : 'xdg-open'
+    execFile(cmd, [url], () => {})
+  }
 }
 
 type WritableLike = Pick<typeof process.stderr, 'write'>