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## Why #2386 added `installSdkIfNeeded()` to build @gsd-build/sdk from bundled source and `npm install -g .`, because the npm-published @gsd-build/sdk is intentionally frozen and version-mismatched with get-shit-done-cc. But every failure path in that function was warning-only — including the final `which gsd-sdk` verification. When npm's global bin is off a user's PATH (common on macOS), the installer printed a yellow warning then exited 0. Users saw "install complete" and then every `/gsd-*` command crashed with `command not found: gsd-sdk` (the #2439 symptom). No CI job executed the install path, so this class of regression could ship undetected — existing "install" tests only read bin/install.js as a string. ## What changed **bin/install.js — installSdkIfNeeded() is now transactional** - All build/install failures exit non-zero (not just warn). - Post-install `which gsd-sdk` check is fatal: if the binary landed globally but is off PATH, we exit 1 with a red banner showing the resolved npm bin dir, the user's shell, the target rc file, and the exact `export PATH=…` line to add. - Escape hatch: `GSD_ALLOW_OFF_PATH=1` downgrades off-PATH to exit 2 for users with intentionally restricted PATH who will wire up the binary manually. - Resolver uses POSIX `command -v` via `sh -c` (replaces `which`) so behavior is consistent across sh/bash/zsh/fish. - Factored `resolveGsdSdk()`, `detectShellRc()`, `emitSdkFatal()`. **.github/workflows/install-smoke.yml (new)** - Executes the real install path: `npm pack` → `npm install -g <tgz>` → run installer non-interactively → `command -v gsd-sdk` → run `gsd-sdk --version`. - PRs: path-filtered to installer-adjacent files, ubuntu + Node 22 only. - main/release branches: full matrix (ubuntu+macos × Node 22+24). - Reusable via workflow_call with `ref` input for release gating. **.github/workflows/release.yml — pre-publish gate** - New `install-smoke-rc` and `install-smoke-finalize` jobs invoke the reusable workflow against the release branch. `rc` and `finalize` now `needs: [validate-version, install-smoke-*]`, so a broken SDK install blocks `npm publish`. ## Test plan - Local full suite: 4154/4154 pass - install-smoke.yml will self-validate on this PR (ubuntu+Node22 only) Addresses root cause of #2439 (the per-command pre-flight in #2440 is the complementary defensive layer). Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>