test: repair route harness error rendering + stop AI-checker spawning real processes in tests (#97)

* fix(test): share route error handler with test harness + fix stale assertions

The route test harness built a bare Fastify instance without the production
global error handler (server.ts), so structured errors thrown by route helpers
(findSessionOrFail → 404, parseBody → 400) fell through to Fastify's default
handler — yielding a `{statusCode,error,message}` body instead of the
`{success:false,...}` shape, and the tests asserted the old implicit-200
behavior. 51 route tests across 7 files were red.

- Extract the handler into src/web/route-error-handler.ts; server.ts and the
  test harness now install the identical handler (single source of truth).
- Correct stale assertions across route test files: throw-based error paths
  now assert 404 (unknown session) / 400 (invalid body); genuine in-handler
  `return createErrorResponse(...)` paths (200 + success:false) left untouched.
- Reformat a few test files prettier flagged (pre-existing non-compliance).

Route suite: 307/307 passing (was 256/307). No production behavior change.

* test(respawn): mock child_process so AI checker never spawns real processes

respawn-controller.test.ts drives the AI idle checker (ai-checker-base), whose
runCheck() spawns a real `tmux new-session` running `claude -p`. The AI-enabled
tests only assert the ai_checking state transition (then cancel/stop), so the
spawn produced stray real tmux sessions and claude processes on every run — the
reason `npm test` (full suite) was unsafe to run inside a managed session.

Mock node:child_process here (mirroring ai-idle-checker.test.ts), spreading the
real module so `exec` stays intact for transitively-imported modules
(tmux-manager calls promisify(exec) at load). With this, the full non-mobile
suite runs without spawning any real tmux/claude.

---------

Co-authored-by: Teigen <teigen@TeigendeMac-mini.local>

test/routes/_route-test-utils.ts

@@ -7,6 +7,7 @@
 import Fastify, { type FastifyInstance } from 'fastify';
 import fastifyCookie from '@fastify/cookie';
 import { createMockRouteContext, type MockRouteContext } from '../mocks/index.js';
+import { installRouteErrorHandler } from '../../src/web/route-error-handler.js';
 
 export interface RouteTestHarness {
   app: FastifyInstance;
@@ -24,7 +25,7 @@ export interface RouteTestHarness {
 export async function createRouteTestHarness(
   // eslint-disable-next-line @typescript-eslint/no-explicit-any
   registerFn: (app: FastifyInstance, ctx: any) => void,
-  ctxOptions?: { sessionId?: string },
+  ctxOptions?: { sessionId?: string }
 ): Promise<RouteTestHarness> {
   const app = Fastify({ logger: false });
 
@@ -34,6 +35,9 @@ export async function createRouteTestHarness(
   const ctx = createMockRouteContext(ctxOptions);
 
   registerFn(app, ctx);
+  // Mirror production: structured errors thrown by route helpers (findSessionOrFail,
+  // parseBody) are rendered to {success:false} bodies at the right status.
+  installRouteErrorHandler(app);
   await app.ready();
 
   return { app, ctx };