Fix cloudflared detection in packaged app + minor UX improvements

- Fix cloudflared not being found when running from /Applications by using
  expanded PATH (includes /opt/homebrew/bin, /usr/local/bin, etc.) in
  cliDetection.ts, matching how agent-detector.ts handles binary detection
- Cache and use full cloudflared path in tunnel-manager.ts to ensure the
  binary is found when spawning the tunnel process
- Add debugging logs for process exit events to help diagnose thinking pill
  issues (App.tsx)
- Add hint about Cmd+/ shortcut in settings modal shortcuts section
- Add Cmd+U shortcut hint to tab filter tooltip

Claude ID: 110ec97f-d876-4fb9-b577-ee7a7cd4f9e5
Maestro ID: b9bc0d08-5be2-4fdf-93cd-5618a8d53b35

src/main/tunnel-manager.ts

@@ -1,5 +1,6 @@
 import { ChildProcess, spawn } from 'child_process';
 import { logger } from './utils/logger';
+import { getCloudflaredPath, isCloudflaredInstalled } from './utils/cliDetection';
 
 export interface TunnelStatus {
   isRunning: boolean;
@@ -27,10 +28,18 @@ class TunnelManager {
     // Stop any existing tunnel first
     await this.stop();
 
-    return new Promise((resolve) => {
-      logger.info(`Starting cloudflared tunnel for port ${port}`, 'TunnelManager');
+    // Ensure cloudflared is installed and get its path
+    const installed = await isCloudflaredInstalled();
+    if (!installed) {
+      return { success: false, error: 'cloudflared is not installed' };
+    }
 
-      this.process = spawn('cloudflared', [
+    const cloudflaredBinary = getCloudflaredPath() || 'cloudflared';
+
+    return new Promise((resolve) => {
+      logger.info(`Starting cloudflared tunnel for port ${port} using ${cloudflaredBinary}`, 'TunnelManager');
+
+      this.process = spawn(cloudflaredBinary, [
         'tunnel', '--url', `http://localhost:${port}`
       ]);
 

src/main/utils/cliDetection.ts

@@ -1,6 +1,42 @@
 import { execFileNoThrow } from './execFile';
+import * as os from 'os';
 
 let cloudflaredInstalledCache: boolean | null = null;
+let cloudflaredPathCache: string | null = null;
+
+/**
+ * Build an expanded PATH that includes common binary installation locations.
+ * This is necessary because packaged Electron apps don't inherit shell environment.
+ */
+function getExpandedEnv(): NodeJS.ProcessEnv {
+  const home = os.homedir();
+  const env = { ...process.env };
+
+  const additionalPaths = [
+    '/opt/homebrew/bin',           // Homebrew on Apple Silicon
+    '/opt/homebrew/sbin',
+    '/usr/local/bin',              // Homebrew on Intel, common install location
+    '/usr/local/sbin',
+    `${home}/.local/bin`,          // User local installs
+    `${home}/bin`,                 // User bin directory
+    '/usr/bin',
+    '/bin',
+    '/usr/sbin',
+    '/sbin',
+  ];
+
+  const currentPath = env.PATH || '';
+  const pathParts = currentPath.split(':');
+
+  for (const p of additionalPaths) {
+    if (!pathParts.includes(p)) {
+      pathParts.unshift(p);
+    }
+  }
+
+  env.PATH = pathParts.join(':');
+  return env;
+}
 
 export async function isCloudflaredInstalled(): Promise<boolean> {
   // Return cached result if available
@@ -10,12 +46,23 @@ export async function isCloudflaredInstalled(): Promise<boolean> {
 
   // Use 'which' on macOS/Linux, 'where' on Windows
   const command = process.platform === 'win32' ? 'where' : 'which';
-  const result = await execFileNoThrow(command, ['cloudflared']);
-  cloudflaredInstalledCache = result.exitCode === 0;
+  const env = getExpandedEnv();
+  const result = await execFileNoThrow(command, ['cloudflared'], undefined, env);
+
+  if (result.exitCode === 0 && result.stdout.trim()) {
+    cloudflaredInstalledCache = true;
+    cloudflaredPathCache = result.stdout.trim().split('\n')[0];
+  } else {
+    cloudflaredInstalledCache = false;
+  }
 
   return cloudflaredInstalledCache;
 }
 
+export function getCloudflaredPath(): string | null {
+  return cloudflaredPathCache;
+}
+
 export function clearCloudflaredCache(): void {
   cloudflaredInstalledCache = null;
 }

src/renderer/App.tsx

@@ -669,7 +669,14 @@ export default function MaestroConsole() {
     });
 
     // Handle process exit
-    const unsubscribeExit = window.maestro.process.onExit((sessionId: string, code: number) => {
+    const unsubscribeExit = window.maestro.process.onExit(async (sessionId: string, code: number) => {
+      // Log all exit events to help diagnose thinking pill disappearing prematurely
+      console.log('[onExit] Process exit event received:', {
+        rawSessionId: sessionId,
+        exitCode: code,
+        timestamp: new Date().toISOString()
+      });
+
       // Parse sessionId to determine which process exited
       // Format: {id}-ai-{tabId}, {id}-terminal, {id}-batch-{timestamp}
       let actualSessionId: string;
@@ -693,6 +700,26 @@ export default function MaestroConsole() {
         isFromAi = false;
       }
 
+      // SAFETY CHECK: Verify the process is actually gone before transitioning to idle
+      // This prevents the thinking pill from disappearing while the process is still running
+      // (which can happen if we receive a stale/duplicate exit event)
+      if (isFromAi) {
+        try {
+          const activeProcesses = await window.maestro.process.getActiveProcesses();
+          const processStillRunning = activeProcesses.some(p => p.sessionId === sessionId);
+          if (processStillRunning) {
+            console.warn('[onExit] Process still running despite exit event, ignoring:', {
+              sessionId,
+              activeProcesses: activeProcesses.map(p => p.sessionId)
+            });
+            return;
+          }
+        } catch (error) {
+          console.error('[onExit] Failed to verify process status:', error);
+          // Continue with exit handling if we can't verify - better than getting stuck
+        }
+      }
+
       // For AI exits, gather toast data BEFORE state update to avoid side effects in updater
       // React 18 StrictMode may call state updater functions multiple times
       let toastData: {
@@ -910,6 +937,18 @@ export default function MaestroConsole() {
           const newState = anyTabStillBusy ? 'busy' as SessionState : 'idle' as SessionState;
           const newBusySource = anyTabStillBusy ? s.busySource : undefined;
 
+          // Log state transition for debugging thinking pill issues
+          console.log('[onExit] Session state transition:', {
+            sessionId: s.id.substring(0, 8),
+            tabIdFromSession: tabIdFromSession?.substring(0, 8),
+            previousState: s.state,
+            newState,
+            previousBusySource: s.busySource,
+            newBusySource,
+            anyTabStillBusy,
+            tabStates: updatedAiTabs.map(t => ({ id: t.id.substring(0, 8), state: t.state }))
+          });
+
           // Task complete - also clear pending AI command flag
           return {
             ...s,

src/renderer/components/SettingsModal.tsx

@@ -1273,6 +1273,9 @@ export function SettingsModal(props: SettingsModalProps) {
                     {shortcutsFilter ? `${filteredCount} / ${totalShortcuts}` : totalShortcuts}
                   </span>
                 </div>
+                <p className="text-xs opacity-50 mb-3" style={{ color: theme.colors.textDim }}>
+                  Not all shortcuts can be modified. Press <kbd className="px-1.5 py-0.5 rounded font-mono" style={{ backgroundColor: theme.colors.bgActivity }}>⌘/</kbd> to view the full list of keyboard shortcuts.
+                </p>
                 <div className="space-y-2 flex-1 overflow-y-auto pr-2 scrollbar-thin">
                   {filteredShortcuts.map((sc: Shortcut) => (
                     <div key={sc.id} className="flex items-center justify-between p-3 rounded border" style={{ borderColor: theme.colors.border, backgroundColor: theme.colors.bgMain }}>

src/renderer/components/TabBar.tsx

@@ -651,7 +651,8 @@ export function TabBar({
             zIndex: 6
           }}
         >
-          {showUnreadOnly ? 'Showing unread only' : 'Filter unread tabs'}
+          {showUnreadOnly ? 'Showing unread only' : 'Filter unread tabs'}{' '}
+          <span style={{ color: theme.colors.textDim }}>(Cmd+U)</span>
         </div>
       </div>