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/case-routes.test.ts

@@ -104,9 +104,7 @@ describe('case-routes', () => {
     });
 
     it('includes hasClaudeMd flag', async () => {
-      mockedReaddir.mockResolvedValue([
-        { name: 'case-with-md', isDirectory: () => true },
-      ] as never);
+      mockedReaddir.mockResolvedValue([{ name: 'case-with-md', isDirectory: () => true }] as never);
       mockedExistsSync.mockReturnValue(true);
 
       const res = await harness.app.inject({
@@ -120,9 +118,7 @@ describe('case-routes', () => {
 
     it('includes linked cases from linked-cases.json', async () => {
       // CASES_DIR readdir returns one case
-      mockedReaddir.mockResolvedValue([
-        { name: 'regular-case', isDirectory: () => true },
-      ] as never);
+      mockedReaddir.mockResolvedValue([{ name: 'regular-case', isDirectory: () => true }] as never);
       // linked-cases.json is read second (after CASES_DIR readdir)
       let readCallCount = 0;
       mockedReadFile.mockImplementation(async () => {
@@ -158,7 +154,7 @@ describe('case-routes', () => {
         url: '/api/cases',
         payload: { name: 'invalid case name!!' },
       });
-      expect(res.statusCode).toBe(200);
+      expect(res.statusCode).toBe(400);
       const body = JSON.parse(res.body);
       expect(body.success).toBe(false);
     });
@@ -169,7 +165,7 @@ describe('case-routes', () => {
         url: '/api/cases',
         payload: {},
       });
-      expect(res.statusCode).toBe(200);
+      expect(res.statusCode).toBe(400);
       const body = JSON.parse(res.body);
       expect(body.success).toBe(false);
     });
@@ -180,7 +176,7 @@ describe('case-routes', () => {
         url: '/api/cases',
         payload: { name: '../etc' },
       });
-      expect(res.statusCode).toBe(200);
+      expect(res.statusCode).toBe(400);
       const body = JSON.parse(res.body);
       expect(body.success).toBe(false);
     });
@@ -230,7 +226,7 @@ describe('case-routes', () => {
         url: '/api/cases/link',
         payload: { name: 'bad name!' },
       });
-      expect(res.statusCode).toBe(200);
+      expect(res.statusCode).toBe(400);
       const body = JSON.parse(res.body);
       expect(body.success).toBe(false);
     });
@@ -241,7 +237,7 @@ describe('case-routes', () => {
         url: '/api/cases/link',
         payload: {},
       });
-      expect(res.statusCode).toBe(200);
+      expect(res.statusCode).toBe(400);
       const body = JSON.parse(res.body);
       expect(body.success).toBe(false);
     });
@@ -294,7 +290,10 @@ describe('case-routes', () => {
       const body = JSON.parse(res.body);
       expect(body.success).toBe(true);
       expect(body.data.case.name).toBe('linked-project');
-      expect(harness.ctx.broadcast).toHaveBeenCalledWith('case:linked', expect.objectContaining({ name: 'linked-project' }));
+      expect(harness.ctx.broadcast).toHaveBeenCalledWith(
+        'case:linked',
+        expect.objectContaining({ name: 'linked-project' })
+      );
     });
   });