fix(ci): unblock the release — npm 11 esbuild bloat + two self-inflicted assertions

v1.9.0 was tagged but never published: smoke failed 90-passed/3-failed and
build-variant needs smoke, so nothing reached the registry. All three are fixed.

1. Size, 431 MB over threshold. Node 24 brings npm 11, which installs EVERY
   @esbuild/<platform> optional binary instead of the matching one: 26 dirs,
   284 MB per pi-coding-agent copy. Measured on pi-fork: npm 10.9.8 -> 165 MB
   (exactly what v1.8.14 shipped), npm 11.19.0 -> 449 MB. npm 11 ignores the
   os/cpu constraints AND --os/--cpu AND an npmrc carrying them, all measured,
   so Dockerfile.variant prunes explicitly, keeping linux-$(node -p
   process.arch) so one line is right on both arches. Pruned in the SAME layer
   as each install, or the bytes survive in the earlier layer. Three sites:
   global pi, pi-fork, pi-studio. Verified esbuild still transforms TS after.

2. om's node_modules assertion tested an npm artefact. om has zero runtime deps;
   its node_modules held ONE file (.package-lock.json) and 20 empty scope dirs.
   npm 11 stopped creating it. Now asserts the entry point pi actually loads,
   read from package.json -> pi.extensions.

3. The skill-source annotation added in v1.9.0 ("baked (package copy)") broke
   the assertion matching "baked$". Pattern now allows an optional suffix; which
   copy shipped stays authoritatively asserted against the manifest + tree hash.

Also: a failed size check now prints the largest layers, largest directories and
an @esbuild sentinel, so this class attributes itself next time instead of
costing a CI dig plus a local npm bisect.

Threshold stays 3800 MB: it caught a real regression and raising it would have
thrown the signal away. No Dockerfile.base/rootfs change, so base-0fb1256c7f99
is reused and build-base is skipped.

scripts/smoke-test.sh

@@ -315,8 +315,24 @@ run "pi-toolkit clone"    "test -d /opt/pi-toolkit && git -C /opt/pi-toolkit rev
 run "pi-extensions clone" "test -d /opt/pi-extensions && git -C /opt/pi-extensions rev-parse --short HEAD"
 run "pi-fork clone + node_modules" \
     "test -f /opt/pi-fork/package.json && test -d /opt/pi-fork/node_modules"
-run "pi-observational-memory clone + node_modules" \
-    "test -f /opt/pi-observational-memory/package.json && test -d /opt/pi-observational-memory/node_modules"
+# om is checked differently from pi-fork ON PURPOSE. It declares ZERO runtime
+# dependencies: 8 devDependencies (omitted by --omit=dev) and 4 peerDependencies,
+# which pi itself provides. npm 10 still materialised a node_modules for it, but
+# that directory held exactly ONE file (.package-lock.json, 4 KB) and no nested
+# package.json at all — 20 empty scope dirs. npm 11 stopped creating it, so the
+# old `test -d node_modules` assertion went red on v1.9.0 while nothing about om
+# had changed or broken. It was asserting an npm artefact, not a property of the
+# shipped software. What actually has to hold is that the entry point pi loads
+# exists, so assert THAT, straight out of the manifest pi reads
+# (package.json -> pi.extensions), rather than a hardcoded path that could drift.
+run "pi-observational-memory clone + declared pi entry point" \
+    "test -f /opt/pi-observational-memory/package.json && \
+     node -e 'const p=require(\"/opt/pi-observational-memory/package.json\"),f=require(\"fs\"),h=require(\"path\"); \
+              const l=(p.pi&&p.pi.extensions)||[]; \
+              if(!l.length){console.error(\"package.json declares no pi.extensions\");process.exit(1)} \
+              for(const e of l){const t=h.resolve(\"/opt/pi-observational-memory\",e); \
+                if(!f.existsSync(t)){console.error(\"declared entry missing: \"+t);process.exit(1)}} \
+              console.log(\"entries ok: \"+l.join(\",\"))'"
 # ...and that the clone carries the AUTH FIX, not merely that it exists. om's
 # pre-flight hasUsableAuth() check silently disabled `recall` for ~8 weeks once
 # pi moved to request-time SigV4 signing and stopped exposing a static Bedrock
@@ -697,9 +713,17 @@ exec_test "pi-devbox-version reports skill sources (all baked, no skillset here)
     'out=$(pi-devbox-version)
      echo "$out" | grep -q "skills:" || { echo "no skills section" >&2; exit 1; }
      for s in mempalace pi-extensions pi-devbox-environment credential-incident-response; do
-       echo "$out" | grep -qE "^    $s +baked$" \
+       echo "$out" | grep -qE "^    $s +baked( \([^)]*\))?$" \
          || { echo "$s not reported as baked" >&2; exit 1; }
      done; echo ok'
+# The optional " (...)" above is what pi-extensions now appends to say WHICH copy
+# shipped — "baked (package copy)", or a loud FALLBACK/MIXED annotation. Without
+# allowing it, adding that annotation turned this assertion red on v1.9.0 even
+# though the state it reported was the correct one. The suffix is deliberately
+# matched loosely rather than pinned to "(package copy)", because WHICH copy
+# shipped is already asserted authoritatively above, against the manifest field
+# and its measured tree hash, and duplicating that here in a regex would just
+# create a second place to update whenever the wording changes.
 # The boot banner must NOT carry the section: entrypoint-user.sh prints the
 # version FIRST, before the baked links exist and long before the skillset
 # deploy + reconcile run last, so anything it said about skill sources would be
@@ -882,6 +906,24 @@ elif [ "$SIZE_MB" -le "$SIZE_THRESHOLD_MB" ]; then
   printf "  ✅  size: %d MB (threshold %d MB)\n" "$SIZE_MB" "$SIZE_THRESHOLD_MB"; PASS=$((PASS+1))
 else
   printf "  ❌  size: %d MB exceeds threshold %d MB\n" "$SIZE_MB" "$SIZE_THRESHOLD_MB"; FAIL=$((FAIL+1))
+  # A bare "too big" verdict cost a full CI-log dig plus a local npm bisect to
+  # attribute the v1.9.0 overshoot (+431 MB, which turned out to be npm 11
+  # installing 26 @esbuild platform binaries per pi-coding-agent copy). The
+  # container already knows where its bytes are, so make it say so: the biggest
+  # layers, and the biggest directories under the paths that historically grow.
+  # Same principle as the run() helper above — a red assertion should carry its
+  # own diagnostic rather than send the next reader spelunking.
+  echo "      ── largest layers (docker history) ──"
+  docker history --format '{{.Size}}\t{{.CreatedBy}}' "$IMAGE" 2>/dev/null \
+    | grep -vE '^0B' | head -12 | sed 's/^/        /' | cut -c1-160
+  echo "      ── largest directories in the image ──"
+  docker run --rm --entrypoint sh "$IMAGE" -c \
+    'du -sm /usr/lib/node_modules/* /opt/* /usr/local/share/ms-playwright 2>/dev/null | sort -rn | head -12' \
+    2>/dev/null | sed 's/^/        /' || echo "        (could not inspect directories)"
+  echo "      ── @esbuild platform dirs (npm 11 regression sentinel) ──"
+  docker run --rm --entrypoint sh "$IMAGE" -c \
+    'find /usr/lib/node_modules /opt -type d -regex ".*/@esbuild/[^/]+" -printf "%f\n" 2>/dev/null | sort | uniq -c | sort -rn | head' \
+    2>/dev/null | sed 's/^/        /' || true
 fi
 
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