Align upgrade command spawning with create-astro

.changeset/harden-upgrade-command-spawning.md

@@ -0,0 +1,5 @@
+---
+'@astrojs/upgrade': patch
+---
+
+Improves how `@astrojs/upgrade` spawns package manager commands so it uses the same Windows command resolution as `create-astro`

packages/upgrade/src/shell.ts

@@ -5,6 +5,10 @@ import { spawn } from 'node:child_process';
 import type { Readable } from 'node:stream';
 import { text as textFromStream } from 'node:stream/consumers';
 
+const WINDOWS_CMD_SHIMS = new Set(['npm', 'npx', 'pnpm', 'pnpx', 'yarn', 'yarnpkg']);
+// Bun ships as .exe on Windows, not .cmd, so it can be spawned directly with the .exe extension
+const WINDOWS_EXE_SHIMS = new Set(['bun', 'bunx']);
+
 interface ExecaOptions {
 	cwd?: string | URL;
 	stdio?: StdioOptions;
@@ -18,7 +22,27 @@ interface Output {
 const text = (stream: NodeJS.ReadableStream | Readable | null) =>
 	stream ? textFromStream(stream).then((t) => t.trimEnd()) : '';
 
-let signal: AbortSignal;
+/**
+ * On Windows, `.cmd` and `.bat` files cannot be spawned directly without a shell.
+ * For known package manager shims, we invoke them via `cmd.exe /d /s /c` instead.
+ * Bun ships as `.exe` on Windows (not `.cmd`), so it can be spawned directly.
+ * Returns [resolvedCommand, resolvedFlags] to use with spawn.
+ */
+function resolveCommand(command: string, flags: string[]): [string, string[]] {
+	if (process.platform !== 'win32') return [command, flags];
+	if (command.includes('/') || command.includes('\\') || command.includes('.')) {
+		return [command, flags];
+	}
+	const cmd = command.toLowerCase();
+	if (WINDOWS_CMD_SHIMS.has(cmd)) {
+		return ['cmd.exe', ['/d', '/s', '/c', `${command}.cmd`, ...flags]];
+	}
+	if (WINDOWS_EXE_SHIMS.has(cmd)) {
+		return [`${command}.exe`, flags];
+	}
+	return [command, flags];
+}
+
 export async function shell(
 	command: string,
 	flags: string[],
@@ -27,33 +51,28 @@ export async function shell(
 	let child: ChildProcess;
 	let stdout = '';
 	let stderr = '';
-	if (!signal) {
-		const controller = new AbortController();
-		// Ensure spawned process is cancelled on exit
-		process.once('beforeexit', () => controller.abort());
-		process.once('exit', () => controller.abort());
-		signal = controller.signal;
-	}
 	try {
-		child = spawn(`${command} ${flags.join(' ')}`, {
+		const [resolvedCommand, resolvedFlags] = resolveCommand(command, flags);
+		child = spawn(resolvedCommand, resolvedFlags, {
 			cwd: opts.cwd,
-			shell: true,
 			stdio: opts.stdio,
 			timeout: opts.timeout,
-			signal,
 		});
-		const done = new Promise((resolve) => child.on('close', resolve));
-		[stdout, stderr] = await Promise.all([text(child.stdout), text(child.stderr)]);
-		await done;
-	} catch {
-		throw { stdout, stderr, exitCode: 1 };
+		const done = new Promise<void>((resolve, reject) => {
+			child.once('error', reject);
+			child.once('close', () => resolve());
+		});
+		[stdout, stderr] = await Promise.all([text(child.stdout), text(child.stderr), done]);
+	} catch (e) {
+		const message = e instanceof Error ? e.message : stderr || 'Unknown error';
+		throw new Error(message);
 	}
 	const { exitCode } = child;
 	if (exitCode === null) {
 		throw new Error('Timeout');
 	}
 	if (exitCode !== 0) {
-		throw new Error(stderr);
+		throw new Error(stderr || `Process exited with code ${exitCode}`);
 	}
 	return { stdout, stderr, exitCode };
 }