fix: persist onboard_completed to bootstrap .env so config survives restart (#241)

* fix: persist onboard_completed to bootstrap .env so config survives restart (#187)

The wizard saved settings to the database but check_onboard_needed() read
from the legacy settings.json on disk, causing re-onboarding on every run
for non-NEAR AI users. Write ONBOARD_COMPLETED=true to ~/.ironclaw/.env
and check that env var instead of the legacy file.

Co-Authored-By: Claude Opus 4.6 <[email protected]>

* Apply suggestion from @Copilot

Co-authored-by: Copilot <[email protected]>

---------

Co-authored-by: Claude Opus 4.6 <[email protected]>
Co-authored-by: Copilot <[email protected]>

src/bootstrap.rs

@@ -492,4 +492,32 @@ INJECTED="pwned"#;
         assert_eq!(parsed.len(), 2);
         assert!(parsed.iter().all(|(k, _)| k != "DATABASE_URL"));
     }
+
+    #[test]
+    fn test_onboard_completed_round_trips_through_env() {
+        let dir = tempdir().unwrap();
+        let env_path = dir.path().join(".env");
+
+        // Simulate what the wizard writes: bootstrap vars + ONBOARD_COMPLETED
+        let vars = [
+            ("DATABASE_BACKEND", "libsql"),
+            ("ONBOARD_COMPLETED", "true"),
+        ];
+        let mut content = String::new();
+        for (key, value) in &vars {
+            let escaped = value.replace('\\', "\\\\").replace('"', "\\\"");
+            content.push_str(&format!("{}=\"{}\"\n", key, escaped));
+        }
+        std::fs::write(&env_path, &content).unwrap();
+
+        // Verify dotenvy parses ONBOARD_COMPLETED correctly
+        let parsed: Vec<(String, String)> = dotenvy::from_path_iter(&env_path)
+            .unwrap()
+            .filter_map(|r| r.ok())
+            .collect();
+        assert_eq!(parsed.len(), 2);
+        let onboard = parsed.iter().find(|(k, _)| k == "ONBOARD_COMPLETED");
+        assert!(onboard.is_some(), "ONBOARD_COMPLETED must be present");
+        assert_eq!(onboard.unwrap().1, "true");
+    }
 }

src/main.rs

@@ -1575,14 +1575,21 @@ fn check_onboard_needed() -> Option<&'static str> {
         return Some("Database not configured");
     }
 
+    // The wizard writes ONBOARD_COMPLETED=true to ~/.ironclaw/.env,
+    // which load_ironclaw_env() loads before this function runs.
+    if std::env::var("ONBOARD_COMPLETED")
+        .map(|v| v == "true")
+        .unwrap_or(false)
+    {
+        return None;
+    }
+
     // First run (onboarding never completed and no session).
-    // Reads NEARAI_API_KEY env var directly because this function runs
-    // before Config is loaded -- Config::from_env() may fail without a
-    // database URL, which is what triggers onboarding in the first place.
+    // Check for a NEAR AI API key or session file as a fallback
+    // for users who configured credentials manually (no wizard).
     if std::env::var("NEARAI_API_KEY").is_err() {
-        let settings = ironclaw::settings::Settings::load();
         let session_path = ironclaw::llm::session::default_session_path();
-        if !settings.onboard_completed && !session_path.exists() {
+        if !session_path.exists() {
             return Some("First run");
         }
     }

src/setup/README.md

@@ -19,8 +19,9 @@ Explicit invocation. Loads `.env` files, runs the wizard, exits.
 ironclaw          (first run, no database configured)
 ```
 
-Auto-detection via `check_onboard_needed()` in `main.rs`. Triggers when
-none of these are true:
+Auto-detection via `check_onboard_needed()` in `main.rs`. Skips onboarding
+when `ONBOARD_COMPLETED` env var is set (written to `~/.ironclaw/.env` by
+the wizard). Otherwise triggers when no database is configured:
 - `DATABASE_URL` env var is set
 - `LIBSQL_PATH` env var is set
 - `~/.ironclaw/ironclaw.db` exists on disk
@@ -345,13 +346,14 @@ Final step of the wizard:
 1. Mark onboard_completed = true
 2. Write ALL settings to database (try postgres pool, then libSQL backend)
 3. Write bootstrap vars to ~/.ironclaw/.env:
-   - DATABASE_BACKEND (always)
-   - DATABASE_URL     (if postgres)
-   - LIBSQL_PATH      (if libsql)
-   - LIBSQL_URL       (if turso sync)
-   - LLM_BACKEND      (always, when set)
-   - LLM_BASE_URL     (if openai_compatible)
-   - OLLAMA_BASE_URL   (if ollama)
+   - DATABASE_BACKEND   (always)
+   - DATABASE_URL       (if postgres)
+   - LIBSQL_PATH        (if libsql)
+   - LIBSQL_URL         (if turso sync)
+   - LLM_BACKEND        (always, when set)
+   - LLM_BASE_URL       (if openai_compatible)
+   - OLLAMA_BASE_URL    (if ollama)
+   - ONBOARD_COMPLETED  (always, "true")
 4. Print configuration summary
 ```
 

src/setup/wizard.rs

@@ -1542,6 +1542,10 @@ impl SetupWizard {
                 env_vars.push(("OLLAMA_BASE_URL", url.clone()));
             }
 
+            // Always write ONBOARD_COMPLETED so that check_onboard_needed()
+            // (which runs before the DB is connected) knows to skip re-onboarding.
+            env_vars.push(("ONBOARD_COMPLETED", "true".to_string()));
+
             if !env_vars.is_empty() {
                 let pairs: Vec<(&str, &str)> =
                     env_vars.iter().map(|(k, v)| (*k, v.as_str())).collect();