fix(installer): resolve Windows installation and upgrade failures

install.ps1

@@ -38,11 +38,17 @@ function Write-Die {
 # ── Platform / architecture detection ─────────────────────────────────────────
 
 function Get-PlatformTriple {
-    $arch = [System.Runtime.InteropServices.RuntimeInformation]::ProcessArchitecture
+    # RuntimeInformation.ProcessArchitecture can be unavailable in Windows PowerShell 5.1.
+    # WOW64 exposes the native architecture separately from the 32-bit process.
+    $arch = $env:PROCESSOR_ARCHITEW6432
+    if (-not $arch) { $arch = $env:PROCESSOR_ARCHITECTURE }
+    if (-not $arch) {
+        Write-Die "could not detect Windows architecture: PROCESSOR_ARCHITEW6432 and PROCESSOR_ARCHITECTURE are empty"
+    }
 
     switch ($arch) {
-        "X64"  { $archId = "x64" }
-        "Arm64" { $archId = "arm64" }
+        "AMD64" { $archId = "x64" }
+        "ARM64" { $archId = "arm64" }
         default { Write-Die "unsupported architecture: $arch (x64 and ARM64 only)" }
     }
 
@@ -67,25 +73,21 @@ function Add-ToUserPath {
 
     $currentUserPath = @([Environment]::GetEnvironmentVariable("PATH", "User") -split ";" | Where-Object { $_ })
 
-    if ($currentUserPath -contains $Dir) {
-        Write-Log "$Dir is already in your user PATH"
+    $newUserPath = (@($Dir) + @($currentUserPath | Where-Object { $_ -ine $Dir })) -join ";"
+    if (($currentUserPath -join ";") -ceq $newUserPath) {
+        Write-Log "$Dir is already first in your user PATH"
         return
     }
 
-    $newUserPath = ($currentUserPath + $Dir) -join ";"
     [Environment]::SetEnvironmentVariable("PATH", $newUserPath, "User")
-    Write-Log "added ${Dir} to user PATH"
+    Write-Log "placed ${Dir} first in user PATH"
 }
 
 function Add-ToSessionPath {
     param([string]$Dir)
 
-    $pathEntries = $env:PATH -split ";" | Where-Object { $_ }
-    if ($pathEntries -contains $Dir) {
-        return
-    }
-
-    $env:PATH = "$Dir;$env:PATH"
+    $pathEntries = @($env:PATH -split ";" | Where-Object { $_ -and $_ -ine $Dir })
+    $env:PATH = (@($Dir) + $pathEntries) -join ";"
 }
 
 # ── Git Bash (bash environment) PATH helper ──────────────────────────────────
@@ -126,14 +128,19 @@ function Install-Binary {
     $staged = "$Target.install-$([Guid]::NewGuid().ToString('N'))"
     try {
         [System.IO.File]::Copy($Source, $staged)
+        # The running daemon may come from another installation directory.
+        # Use the downloaded CLI: older versions have broken Windows liveness checks.
+        # Stop verifies daemon identity and uses the current BSK_HOME.
+        # Fail closed for both new installs and replacements; never discard daemon metadata here.
+        & $Source daemon stop
+        if ($LASTEXITCODE -ne 0) {
+            $daemonHome = if ($env:BSK_HOME) { $env:BSK_HOME } else { Join-Path $HOME ".bsk" }
+            $daemonInfoPath = $ExecutionContext.SessionState.Path.GetUnresolvedProviderPathFromPSPath((Join-Path $daemonHome "daemon.json"))
+            throw "could not stop bsk daemon; installation was not changed. Stop any running bsk daemon, remove '$daemonInfoPath', then retry the installer."
+        }
         if ([System.IO.File]::Exists($Target)) {
-            # Use the downloaded CLI: older versions have broken Windows
-            # liveness checks. Stop verifies daemon identity before terminating it.
-            & $Source daemon stop
-            if ($LASTEXITCODE -ne 0) { throw "could not stop bsk daemon; existing installation was not replaced" }
             # PowerShell 5.1 converts $null to an empty path for string parameters.
             [System.IO.File]::Replace($staged, $Target, [NullString]::Value)
-            Write-Log "daemon will restart automatically on the next browser command"
         }
         else {
             [System.IO.File]::Move($staged, $Target)
@@ -166,14 +173,20 @@ function Main {
         Write-Log "latest version is ${version}"
     }
 
-    $archiveName = "bsk-v${version}-$($platform.TargetTriple).zip"
-    $downloadUrl = "${GitHub}/releases/download/${tag}/${archiveName}"
-
-    $expectedSha = $null
     $platformKey = $platform.PlatformKey
+    $asset = $null
     if ($manifest -and $manifest.assets) {
-        $expectedSha = $manifest.assets.$platformKey.sha256
+        $asset = $manifest.assets.$platformKey
     }
+    # ARM64 is not in the current release matrix. Require a published entry
+    # before attempting it, while preserving legacy x64 installs without a manifest.
+    if ($platform.ArchId -eq "arm64" -and -not $asset) {
+        Write-Die "version.json does not list a Windows ARM64 package for bsk $version"
+    }
+
+    $archiveName = "bsk-v${version}-$($platform.TargetTriple).zip"
+    $downloadUrl = "${GitHub}/releases/download/${tag}/${archiveName}"
+    $expectedSha = if ($asset) { $asset.sha256 } else { $null }
     if (-not $expectedSha) {
         if (-not $manifest) {
             Write-Log "warning: could not fetch version.json; skipping checksum verification"
@@ -184,17 +197,21 @@ function Main {
     }
 
     $tempDir = Join-Path ([System.IO.Path]::GetTempPath()) ([System.IO.Path]::GetRandomFileName())
-    New-Item -ItemType Directory -Path $tempDir -Force | Out-Null
+    [System.IO.Directory]::CreateDirectory($tempDir) | Out-Null
 
     try {
         $archivePath = Join-Path $tempDir $archiveName
 
         Write-Log "downloading ${downloadUrl}"
-        Invoke-WebRequest -Uri $downloadUrl -OutFile $archivePath -UseBasicParsing -ErrorAction Stop
+        # PowerShell 5.1's -OutFile treats brackets as wildcards. Write raw HTTP bytes literally.
+        $response = Invoke-WebRequest -Uri $downloadUrl -UseBasicParsing -ErrorAction Stop
+        try {
+            [System.IO.File]::WriteAllBytes($archivePath, $response.RawContentStream.ToArray())
+        } finally { $response.RawContentStream.Dispose() }
 
         if ($expectedSha) {
             Write-Log "verifying checksum"
-            $actualSha = (Get-FileHash -Algorithm SHA256 -Path $archivePath).Hash
+            $actualSha = (Get-FileHash -Algorithm SHA256 -LiteralPath $archivePath).Hash
             if ($actualSha -ieq $expectedSha) {
                 Write-Log "checksum OK"
             }
@@ -204,15 +221,15 @@ function Main {
         }
 
         Write-Log "extracting ${archiveName}"
-        Expand-Archive -Path $archivePath -DestinationPath $tempDir -Force
+        # PowerShell 5.1's Expand-Archive treats the destination as a wildcard path.
+        Add-Type -AssemblyName System.IO.Compression.FileSystem
+        [System.IO.Compression.ZipFile]::ExtractToDirectory($archivePath, $tempDir)
 
-        if (-not (Test-Path (Join-Path $tempDir "bsk.exe"))) {
+        if (-not (Test-Path -LiteralPath (Join-Path $tempDir "bsk.exe"))) {
             Write-Die "bsk.exe not found in archive"
         }
 
-        if (-not (Test-Path $InstallDir)) {
-            New-Item -ItemType Directory -Path $InstallDir -Force | Out-Null
-        }
+        [System.IO.Directory]::CreateDirectory($InstallDir) | Out-Null
 
         Install-Binary -Source (Join-Path $tempDir "bsk.exe") -Target (Join-Path $InstallDir "bsk.exe")
 
@@ -232,12 +249,18 @@ function Main {
         & $bskPath --version
         if ($LASTEXITCODE -ne 0) { throw "installed bsk failed verification" }
 
+        $command = Get-Command bsk -ErrorAction SilentlyContinue
+        if (-not $command -or $command.CommandType -ne "Application" -or $command.Source -ine $bskPath) {
+            Write-Log "warning: 'bsk' does not resolve to $bskPath in this session; check Get-Command bsk -All for a conflicting command"
+        }
+
         Write-Log "done"
         Write-Host ""
-        Write-Host "Open a new terminal (PowerShell / Git Bash) for PATH changes to take full effect."
+        Write-Host "This PATH check covers the current session only; a new terminal may prefer a Machine PATH entry or alias."
+        Write-Host "In a new PowerShell terminal, run Get-Command bsk -All and confirm the first result is $bskPath."
     }
     finally {
-        Remove-Item -Recurse -Force $tempDir -ErrorAction SilentlyContinue
+        Remove-Item -LiteralPath $tempDir -Recurse -Force -ErrorAction SilentlyContinue
     }
 }