Summary

openclaw doctor mangles long file paths inside note(...) boxes because the downstream clackNote() call re-wraps text that wrapNoteMessage() already correctly preserved. The fix replaces the @clack/prompts note box rendering with an OpenClaw-owned box renderer so copy-sensitive tokens (paths, URLs) stay intact.

Fixes #94730

Root cause

wrapNoteMessage in packages/terminal-core/src/note.ts correctly identifies copy-sensitive tokens (paths starting with /, ~/, ./, URLs, Windows drives, etc.) and allows them to overflow the wrap width rather than being broken mid-token. However, note() then calls clackNote() which performs its own width-based wrapping via fast-wrap-ansi, unaware of the copy-sensitive semantics. The double-wrap causes the path to be split at the box border, breaking file extensions like .jsonl.lock into .js + onl.lock.

Fix

Remove the clackNote() call and build the bordered note box directly in renderNoteBox(). The new renderer:

• Uses the output of wrapNoteMessage() as-is (no re-wrapping)
• Allows lines containing copy-sensitive tokens to overflow the box right border
• Renders the same visual format (◇ Title ─╮, │ content │, ╰───╯)
• Supports rich (colored) and plain terminal output via the existing theme/isRich helpers

Real behavior proof

Behavior addressed: Copy-sensitive file paths were split mid-extension inside openclaw doctor note boxes

Real setup tested:

• Runtime: Node 22.19+, Linux
• Environment: 80-column terminal (COLUMNS=80)

Exact steps or command run after fix:

pnpm test packages/terminal-core/src/note.test.ts

After-fix evidence:

✓ |unit| packages/terminal-core/src/note.test.ts (9 tests) 151ms
  ✓ wrapNoteMessage (3)
    ✓ preserves a copy-sensitive path that exceeds the wrap width
    ✓ preserves a URL that exceeds the wrap width
    ✓ wraps long non-copy-sensitive words at the wrap width
  ✓ note box rendering (4)
    ✓ renders a note box with title and message
    ✓ renders content lines with proper box borders
    ✓ does not re-wrap a copy-sensitive path inside the box
    ✓ allows a copy-sensitive line to overflow the box right border
  ✓ note suppression (2)
    ✓ suppresses output when OPENCLAW_SUPPRESS_NOTES is set
    ✓ suppresses output inside withSuppressedNotes callback

Observed result after the fix: All 9 tests pass. The .jsonl.lock path remains unbroken in the box. Copy-sensitive overflow lines extend past the right border without being split. No regressions in wrapNoteMessage or note suppression behavior.

What was not tested: Full end-to-end openclaw doctor run with a real gateway session lock. The box rendering is verified via unit tests that exercise the exact same code path used by src/commands/doctor-session-locks.ts.

Tests and validation

• New test file: packages/terminal-core/src/note.test.ts (9 tests)
  • 3 tests for wrapNoteMessage (path, URL, long-word wrapping)
  • 4 tests for note() box rendering (title, borders, path preservation, overflow)
  • 2 tests for note suppression (env var, AsyncLocalStorage)
• TypeScript: pnpm tsgo — no errors related to note.ts
• Regression: All existing terminal-core tests pass

Risk checklist

Did user-visible behavior change? Yes — copy-sensitive paths inside note boxes are no longer split; they overflow the right border instead.

Did config, environment, or migration behavior change? No

Did security, auth, secrets, network, or tool execution behavior change? No

What is the highest-risk area?

• Visual rendering of note boxes may differ slightly from @clack/prompts in edge cases (e.g., very narrow terminals, right-to-left text).

How is that risk mitigated?

• The box format uses the same Unicode characters and layout measurements as @clack/prompts.
• Test coverage validates title, content, borders, and overflow behavior.
• The note() function signature is unchanged; callers are unaffected.

Current review state

• Maintainer review