From 0088865e0f2aac1111d413bdf79302c74a46179c Mon Sep 17 00:00:00 2001
From: Colby McHenry <me@colbymchenry.com>
Date: Fri, 22 May 2026 05:39:06 -0500
Subject: [PATCH] fix: prevent V8 turboshaft WASM Zone OOM during indexing
 (#298, #293)
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Large multi-language indexes crashed with `Fatal process out of memory:
Zone` on Node 22/24 (including the bundled runtime) — V8's turboshaft
optimizing WASM compiler exhausts its per-compilation Zone arena while
compiling tree-sitter grammars on a background thread, even with tens of
GB free (the Zone is a V8-internal arena, not the JS heap).

Run node with V8 `--liftoff-only`, which keeps grammar compilation on the
Liftoff baseline and never reaches the optimizing tier. Delivered via the
bundled launcher + a one-shot CLI re-exec guard for all other launch
paths. Empirically only `--liftoff-only` stops it (`--no-wasm-tier-up` /
`--no-wasm-dynamic-tiering` do not), and it must be on node's command
line (setFlagsFromString / worker execArgv / NODE_OPTIONS all fail).

Reproduced the exact crash with the real indexer on Node 24.16 against a
2,880-file / 18-language repo and confirmed the fix eliminates it; full
suite + 7 new tests pass. Bumps to 0.9.4.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
---
 CHANGELOG.md                         | 21 ++++++
 __tests__/wasm-runtime-flags.test.ts | 87 +++++++++++++++++++++++++
 package-lock.json                    |  4 +-
 package.json                         |  2 +-
 scripts/build-bundle.sh              | 14 +++-
 scripts/npm-shim.js                  |  5 +-
 src/bin/codegraph.ts                 |  8 +++
 src/extraction/wasm-runtime-flags.ts | 96 ++++++++++++++++++++++++++++
 8 files changed, 231 insertions(+), 6 deletions(-)
 create mode 100644 __tests__/wasm-runtime-flags.test.ts
 create mode 100644 src/extraction/wasm-runtime-flags.ts

diff --git a/CHANGELOG.md b/CHANGELOG.md
index df3096814..93e558a08 100644
--- a/CHANGELOG.md
+++ b/CHANGELOG.md
@@ -7,6 +7,26 @@ a [GitHub Release](https://github.com/colbymchenry/codegraph/releases) tagged
 This project follows [Keep a Changelog](https://keepachangelog.com/en/1.1.0/)
 and adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0.html).
 
+## [0.9.4] - 2026-05-22
+
+### Fixed
+- **`Fatal process out of memory: Zone` crash while indexing large projects.**
+  On Node.js 22 and 24 — including CodeGraph's own bundled runtime — running
+  `codegraph index` / `codegraph init` on a large multi-language repo could
+  abort the entire process partway through parsing with
+  `Fatal process out of memory: Zone`, even with tens of GB of RAM free (the
+  failure is in a V8-internal compilation arena, not the JS heap). The cause is
+  V8's "turboshaft" optimizing WASM compiler exhausting its Zone budget while
+  compiling tree-sitter's large WebAssembly grammars on a background thread.
+  CodeGraph now runs with V8's `--liftoff-only`, which keeps grammar compilation
+  on the baseline compiler and never reaches the optimizing tier, eliminating
+  the crash; indexing output is otherwise unchanged. The bundled launcher passes
+  the flag directly, and any other launch path (from source, `npx`, a globally
+  linked dev build) re-execs once with it automatically. Resolves
+  [#298](https://github.com/colbymchenry/codegraph/issues/298) and
+  [#293](https://github.com/colbymchenry/codegraph/issues/293). (Node 25 stays
+  blocked — its variant of this V8 bug is not resolved by `--liftoff-only`.)
+
 ## [0.9.3] - 2026-05-22
 
 ### Added
@@ -116,6 +136,7 @@ and adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0.html).
   find its bundle. The release pipeline now verifies every package reached the
   registry (and is idempotent), so a release can't pass green-but-broken again.
 
+[0.9.4]: https://github.com/colbymchenry/codegraph/releases/tag/v0.9.4
 [0.9.3]: https://github.com/colbymchenry/codegraph/releases/tag/v0.9.3
 [0.9.2]: https://github.com/colbymchenry/codegraph/releases/tag/v0.9.2
 [0.9.1]: https://github.com/colbymchenry/codegraph/releases/tag/v0.9.1
diff --git a/__tests__/wasm-runtime-flags.test.ts b/__tests__/wasm-runtime-flags.test.ts
new file mode 100644
index 000000000..a4dae8bba
--- /dev/null
+++ b/__tests__/wasm-runtime-flags.test.ts
@@ -0,0 +1,87 @@
+/**
+ * WASM runtime flags — the workaround for the V8 turboshaft WASM Zone OOM
+ * (`Fatal process out of memory: Zone`) that crashed `codegraph index` on large
+ * polyglot repos under Node >= 22. See issues #293 and #298.
+ *
+ * The crash was reproduced with the real indexer on the bundled Node 24 runtime;
+ * empirically only `--liftoff-only` prevents it (`--no-wasm-tier-up` /
+ * `--no-wasm-dynamic-tiering` do not), and the flag must be on node's command
+ * line — `setFlagsFromString`, worker `execArgv`, and `NODE_OPTIONS` all fail.
+ * These tests pin that contract so it can't silently regress.
+ */
+import { describe, it, expect } from 'vitest';
+import { spawnSync } from 'child_process';
+import * as fs from 'fs';
+import * as os from 'os';
+import * as path from 'path';
+import {
+  WASM_RUNTIME_FLAGS,
+  processHasWasmRuntimeFlags,
+  buildRelaunchArgv,
+} from '../src/extraction/wasm-runtime-flags';
+
+describe('WASM_RUNTIME_FLAGS', () => {
+  it('pins --liftoff-only (the only flag shown to stop the turboshaft Zone OOM)', () => {
+    // On Node 24, --no-wasm-tier-up and --no-wasm-dynamic-tiering both still
+    // crash; only --liftoff-only forces grammars onto the Liftoff baseline and
+    // off the optimizing tier. Pin it so it can't be swapped for an ineffective
+    // flag.
+    expect(WASM_RUNTIME_FLAGS).toContain('--liftoff-only');
+  });
+
+  it('every flag is a real, accepted flag on the running Node/V8 runtime', () => {
+    // node rejects unknown CLI flags at startup, so a renamed/removed flag would
+    // break the bundled launcher and make the relaunch guard a silent no-op.
+    // Prove each flag actually launches node here.
+    const res = spawnSync(
+      process.execPath,
+      [...WASM_RUNTIME_FLAGS, '-e', 'process.exit(0)'],
+      { encoding: 'utf8' }
+    );
+    expect(res.status, `node rejected ${WASM_RUNTIME_FLAGS.join(' ')}:\n${res.stderr}`).toBe(0);
+  });
+});
+
+describe('processHasWasmRuntimeFlags', () => {
+  it('is true only when every required flag is present', () => {
+    expect(processHasWasmRuntimeFlags(['--liftoff-only'])).toBe(true);
+    expect(processHasWasmRuntimeFlags(['--liftoff-only', '--enable-source-maps'])).toBe(true);
+  });
+
+  it('is false when the flags are absent', () => {
+    expect(processHasWasmRuntimeFlags([])).toBe(false);
+    expect(processHasWasmRuntimeFlags(['--max-old-space-size=4096'])).toBe(false);
+  });
+});
+
+describe('buildRelaunchArgv', () => {
+  it('places the wasm flags first, then the script and its args', () => {
+    expect(buildRelaunchArgv('/x/codegraph.js', ['index', '/repo'], [])).toEqual([
+      '--liftoff-only',
+      '/x/codegraph.js',
+      'index',
+      '/repo',
+    ]);
+  });
+
+  it('preserves other existing node flags without duplicating ours', () => {
+    expect(
+      buildRelaunchArgv('/x/codegraph.js', ['status'], ['--liftoff-only', '--enable-source-maps'])
+    ).toEqual(['--liftoff-only', '--enable-source-maps', '/x/codegraph.js', 'status']);
+  });
+
+  it('produces an argv that actually launches node WITH the flag applied', () => {
+    // End-to-end proof of the delivery mechanism without needing the crash:
+    // run the constructed argv and confirm the child sees the flag in execArgv.
+    const dir = fs.mkdtempSync(path.join(os.tmpdir(), 'cg-relaunch-'));
+    try {
+      const harness = path.join(dir, 'harness.cjs');
+      fs.writeFileSync(harness, 'process.stdout.write(JSON.stringify(process.execArgv));');
+      const res = spawnSync(process.execPath, buildRelaunchArgv(harness, []), { encoding: 'utf8' });
+      expect(res.status, res.stderr).toBe(0);
+      expect(JSON.parse(res.stdout)).toContain('--liftoff-only');
+    } finally {
+      fs.rmSync(dir, { recursive: true, force: true });
+    }
+  });
+});
diff --git a/package-lock.json b/package-lock.json
index 36c592b15..cad34c1b5 100644
--- a/package-lock.json
+++ b/package-lock.json
@@ -1,12 +1,12 @@
 {
   "name": "@colbymchenry/codegraph",
-  "version": "0.9.3",
+  "version": "0.9.4",
   "lockfileVersion": 3,
   "requires": true,
   "packages": {
     "": {
       "name": "@colbymchenry/codegraph",
-      "version": "0.9.3",
+      "version": "0.9.4",
       "license": "MIT",
       "dependencies": {
         "@clack/prompts": "^1.3.0",
diff --git a/package.json b/package.json
index f813c1e60..5455ced92 100644
--- a/package.json
+++ b/package.json
@@ -1,6 +1,6 @@
 {
   "name": "@colbymchenry/codegraph",
-  "version": "0.9.3",
+  "version": "0.9.4",
   "description": "Supercharge Claude Code with semantic code intelligence. 94% fewer tool calls • 77% faster exploration • 100% local.",
   "main": "dist/index.js",
   "types": "dist/index.d.ts",
diff --git a/scripts/build-bundle.sh b/scripts/build-bundle.sh
index a00f33695..120ac9810 100755
--- a/scripts/build-bundle.sh
+++ b/scripts/build-bundle.sh
@@ -70,9 +70,18 @@ rm -f "$STAGE/lib/package-lock.json"
 
 # 4. Vendored Node + launcher (the launcher uses the bundled Node by relative
 #    path, so no system Node is ever needed).
+#
+# `--liftoff-only`: keep tree-sitter's large WASM grammars on V8's Liftoff
+# baseline compiler so they never reach the turboshaft optimizing tier, whose
+# per-compilation Zone arena OOMs the whole process (`Fatal process out of
+# memory: Zone`) on Node >= 22 — even with tens of GB free. The flag is read at
+# V8 engine init so it must be on node's command line; the parse worker inherits
+# it. See issues #293/#298 and src/extraction/wasm-runtime-flags.ts. (The CLI
+# also self-relaunches with this flag when launched without it, so non-bundled
+# runs are covered too; passing it here avoids that extra spawn.)
 if [ "$OSFAM" = "win32" ]; then
   cp "$NODE_BIN" "$STAGE/node.exe"
-  printf '@"%%~dp0..\\node.exe" "%%~dp0..\\lib\\dist\\bin\\codegraph.js" %%*\r\n' \
+  printf '@"%%~dp0..\\node.exe" --liftoff-only "%%~dp0..\\lib\\dist\\bin\\codegraph.js" %%*\r\n' \
     > "$STAGE/bin/codegraph.cmd"
 else
   cp "$NODE_BIN" "$STAGE/node"
@@ -89,7 +98,8 @@ while [ -L "$SELF" ]; do
   esac
 done
 DIR="$(cd "$(dirname "$SELF")/.." && pwd)"
-exec "$DIR/node" "$DIR/lib/dist/bin/codegraph.js" "$@"
+# --liftoff-only: avoid the V8 turboshaft WASM Zone OOM (issues #293/#298).
+exec "$DIR/node" --liftoff-only "$DIR/lib/dist/bin/codegraph.js" "$@"
 LAUNCH
   chmod +x "$STAGE/bin/codegraph"
 fi
diff --git a/scripts/npm-shim.js b/scripts/npm-shim.js
index bea905f38..810121245 100755
--- a/scripts/npm-shim.js
+++ b/scripts/npm-shim.js
@@ -31,7 +31,10 @@ try {
   if (isWindows) {
     command = require.resolve(pkg + '/node.exe');
     var entry = require.resolve(pkg + '/lib/dist/bin/codegraph.js');
-    args = [entry].concat(process.argv.slice(2));
+    // --liftoff-only: keep tree-sitter's WASM grammars off V8's turboshaft tier
+    // to avoid the Zone OOM on Node >= 22 (issues #293/#298). The unix launcher
+    // passes this too; on Windows we invoke node.exe directly so add it here.
+    args = ['--liftoff-only', entry].concat(process.argv.slice(2));
   } else {
     command = require.resolve(pkg + '/bin/codegraph');
     args = process.argv.slice(2);
diff --git a/src/bin/codegraph.ts b/src/bin/codegraph.ts
index 6f90e6fe3..711d39c8b 100644
--- a/src/bin/codegraph.ts
+++ b/src/bin/codegraph.ts
@@ -27,6 +27,7 @@ import { createShimmerProgress } from '../ui/shimmer-progress';
 import { getGlyphs } from '../ui/glyphs';
 
 import { buildNode25BlockBanner, buildNodeTooOldBanner, MIN_NODE_MAJOR } from './node-version-check';
+import { relaunchWithWasmRuntimeFlagsIfNeeded } from '../extraction/wasm-runtime-flags';
 
 // Lazy-load heavy modules (CodeGraph, runInstaller) to keep CLI startup fast.
 async function loadCodeGraph(): Promise<typeof import('../index')> {
@@ -75,6 +76,13 @@ if (nodeMajor < MIN_NODE_MAJOR) {
   // Override active — banner shown for visibility, continuing.
 }
 
+// Re-exec with V8's `--liftoff-only` if it isn't already set, so tree-sitter's
+// large WASM grammars never hit the turboshaft Zone OOM (`Fatal process out of
+// memory: Zone`) on Node >= 22. No-op under the bundled launcher, which already
+// passes the flag. Must run before any grammar (in the parse worker, which
+// inherits this process's flags) is compiled. See ../extraction/wasm-runtime-flags.
+relaunchWithWasmRuntimeFlagsIfNeeded(__filename);
+
 // Check if running with no arguments - run installer
 if (process.argv.length === 2) {
   import('../installer').then(({ runInstaller }) =>
diff --git a/src/extraction/wasm-runtime-flags.ts b/src/extraction/wasm-runtime-flags.ts
new file mode 100644
index 000000000..f33a19ff6
--- /dev/null
+++ b/src/extraction/wasm-runtime-flags.ts
@@ -0,0 +1,96 @@
+/**
+ * WASM runtime flags — workaround for the V8 turboshaft WASM Zone OOM.
+ *
+ * tree-sitter grammars are large WebAssembly modules. On Node >= 22 the V8
+ * "turboshaft" optimizing WASM compiler can exhaust its per-compilation Zone
+ * arena while compiling these grammars on a background thread, aborting the
+ * whole process with `Fatal process out of memory: Zone` — even with tens of
+ * GB of system memory free, because the Zone is a V8-internal arena, not the
+ * JS heap. Reproduced on Node 22 and 24; Node 25 is already hard-blocked for
+ * the same crash (see ../bin/node-version-check.ts). See issues #293 and #298.
+ *
+ * `--liftoff-only` forces every WASM module to the Liftoff baseline compiler
+ * and never runs turboshaft, which eliminates the crash. Parsing stays fully
+ * correct; we only forgo the (marginal, and for grammars rarely reached)
+ * optimized-tier speedup.
+ *
+ * This flag MUST be on node's command line — it is read by V8 at engine init,
+ * before any of our JS runs. Empirically (Node 24) none of these work:
+ *   - `v8.setFlagsFromString('--liftoff-only')` at runtime — too late.
+ *   - Worker `execArgv: ['--liftoff-only']` — rejected (ERR_WORKER_INVALID_EXEC_ARGV).
+ *   - `NODE_OPTIONS=--liftoff-only` — not on Node's NODE_OPTIONS allowlist.
+ * Also empirically, `--no-wasm-tier-up` / `--no-wasm-dynamic-tiering` do NOT
+ * prevent the crash — only disabling the optimizing tier entirely does.
+ *
+ * Delivery: the bundled launcher passes the flag directly (see
+ * scripts/build-bundle.sh and scripts/npm-shim.js); for any other launch path
+ * (running dist directly, from source, etc.) the CLI re-execs itself once with
+ * the flag via {@link relaunchWithWasmRuntimeFlagsIfNeeded}. V8 flags are
+ * PROCESS-global, and the parse worker is created with default (inherited)
+ * execArgv, so flagging the main process governs the worker's WASM compilation
+ * too.
+ */
+import { spawnSync } from 'child_process';
+
+/**
+ * The V8 flag(s) that keep tree-sitter grammar compilation off the turboshaft
+ * optimizing tier. Single source of truth: the relaunch guard and the test
+ * suite both read this (a test asserts each is a real flag on the running
+ * runtime, so a rename can't silently regress the fix).
+ */
+export const WASM_RUNTIME_FLAGS: readonly string[] = ['--liftoff-only'];
+
+/**
+ * Env var set on the relaunched child so a detection slip can never cause an
+ * infinite re-exec loop. Also lets users force-disable the relaunch.
+ */
+const RELAUNCH_GUARD_ENV = 'CODEGRAPH_WASM_RELAUNCHED';
+
+/** True when every required WASM runtime flag is already present in `execArgv`. */
+export function processHasWasmRuntimeFlags(
+  execArgv: readonly string[] = process.execArgv
+): boolean {
+  return WASM_RUNTIME_FLAGS.every((flag) => execArgv.includes(flag));
+}
+
+/**
+ * Build the argv for re-execing node with the WASM runtime flags: our flags
+ * first, then any node flags already in `execArgv` (deduped), then the script
+ * and its args. Pure — exported for unit testing.
+ */
+export function buildRelaunchArgv(
+  scriptPath: string,
+  scriptArgs: readonly string[],
+  execArgv: readonly string[] = process.execArgv
+): string[] {
+  const preserved = execArgv.filter((arg) => !WASM_RUNTIME_FLAGS.includes(arg));
+  return [...WASM_RUNTIME_FLAGS, ...preserved, scriptPath, ...scriptArgs];
+}
+
+/**
+ * If the current process is missing the WASM runtime flags, re-exec it once
+ * with them and exit with the child's status. No-op when the flags are already
+ * present (the normal bundled-launcher path), when already relaunched, or when
+ * disabled via CODEGRAPH_NO_RELAUNCH.
+ *
+ * On spawn failure, returns so the caller runs in-process anyway — risking the
+ * OOM is still better than refusing to start.
+ */
+export function relaunchWithWasmRuntimeFlagsIfNeeded(scriptPath: string): void {
+  if (processHasWasmRuntimeFlags()) return;
+  if (process.env[RELAUNCH_GUARD_ENV]) return;
+  if (process.env.CODEGRAPH_NO_RELAUNCH) return;
+
+  const argv = buildRelaunchArgv(scriptPath, process.argv.slice(2));
+  const result = spawnSync(process.execPath, argv, {
+    stdio: 'inherit',
+    env: { ...process.env, [RELAUNCH_GUARD_ENV]: '1' },
+  });
+
+  if (result.error) {
+    // Couldn't relaunch (e.g. execPath unavailable) — fall through and run in
+    // this process. Degraded (may OOM on huge repos) but not broken.
+    return;
+  }
+  process.exit(result.status ?? (result.signal ? 1 : 0));
+}
