From 5e5037b62124127a7382e3f372c6b580325211c3 Mon Sep 17 00:00:00 2001
From: Pablosinyores <nikhilbajaj0182@gmail.com>
Date: Thu, 28 May 2026 19:11:51 +0530
Subject: [PATCH] fix(design/variants): surface real 240s timeout in AbortError
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`generateVariant` in `design/src/variants.ts` arms its abort timer
at 240_000 ms (`setTimeout(() => controller.abort(), 240_000)` at
line 61), but the AbortError branch at line 128 returns
`"Timeout (120s)"` — half the actual bound.

The mismatch is purely a stale string literal, but it's the only
signal a caller gets when the API stalls. A user staring at
`Timeout (120s)` has no way to know whether to bump the orchestrator
timeout, retry, or drop the call — the surfaced number is off by 2x
from the timer that fired.

Surface the real bound: "Timeout (240s)". Adds a regression test that
stubs fetch to a permanently-pending promise, fast-forwards only the
240_000 ms abort timer (leaves the leading exponential retry delays
on their real values), and asserts the surfaced error string matches
the configured bound.
---
 design/src/variants.ts                   |  2 +-
 design/test/variants-retry-after.test.ts | 52 ++++++++++++++++++++++++
 2 files changed, 53 insertions(+), 1 deletion(-)

diff --git a/design/src/variants.ts b/design/src/variants.ts
index 257079dea..c5cafce64 100644
--- a/design/src/variants.ts
+++ b/design/src/variants.ts
@@ -125,7 +125,7 @@ export async function generateVariant(
     } catch (err: any) {
       clearTimeout(timeout);
       if (err.name === "AbortError") {
-        return { path: outputPath, success: false, error: "Timeout (120s)" };
+        return { path: outputPath, success: false, error: "Timeout (240s)" };
       }
       lastError = err.message;
     }
diff --git a/design/test/variants-retry-after.test.ts b/design/test/variants-retry-after.test.ts
index 2060791d5..9a7e05948 100644
--- a/design/test/variants-retry-after.test.ts
+++ b/design/test/variants-retry-after.test.ts
@@ -130,4 +130,56 @@ describe("generateVariant Retry-After handling", () => {
     const gap = calls[1].ts - calls[0].ts;
     expect(gap).toBeLessThan(500);
   });
+
+  test("AbortError surfaces the actual configured 240s timeout in the error message", async () => {
+    // Regression: `generateVariant`'s `setTimeout` aborts at 240_000 ms
+    // (240s) but the AbortError branch returned `"Timeout (120s)"`. A
+    // user staring at the failure has no way to know whether to bump
+    // the orchestrator timeout, retry, or drop the call — the message
+    // is off by 2x. Force the abort path and assert the surfaced
+    // string matches the real bound.
+    const fetchFn = (async (_input: any, init?: any): Promise<Response> => {
+      const signal = init?.signal as AbortSignal | undefined;
+      return await new Promise((_resolve, reject) => {
+        if (signal?.aborted) {
+          const err = new Error("aborted");
+          err.name = "AbortError";
+          reject(err);
+          return;
+        }
+        signal?.addEventListener("abort", () => {
+          const err = new Error("aborted");
+          err.name = "AbortError";
+          reject(err);
+        });
+      });
+    }) as typeof globalThis.fetch;
+
+    const originalSetTimeout = globalThis.setTimeout;
+    // Force the 240_000 ms timer to fire on the next event-loop tick
+    // so the test runs in milliseconds instead of 4 minutes. Only the
+    // 240_000 ms timer maps to fast; the leading exponential delays
+    // (2_000+ ms on retry) keep their real value via this branch
+    // because attempt 0 never sleeps.
+    const fastSetTimeout = ((handler: any, timeout?: number, ...rest: any[]): any => {
+      if (timeout === 240_000) {
+        return originalSetTimeout(handler, 0, ...rest);
+      }
+      return originalSetTimeout(handler, timeout as number, ...rest);
+    }) as typeof globalThis.setTimeout;
+    (globalThis as any).setTimeout = fastSetTimeout;
+
+    try {
+      const result = await generateVariant(
+        "fake-key", "prompt", outputPath, "1024x1024", "high", fetchFn,
+      );
+
+      expect(result.success).toBe(false);
+      // Critical: the message MUST report 240s (the real bound), not
+      // 120s (the pre-fix mismatched literal).
+      expect(result.error).toBe("Timeout (240s)");
+    } finally {
+      (globalThis as any).setTimeout = originalSetTimeout;
+    }
+  });
 });