possible sealsession fix

src/server/session-config.ts

@@ -1,5 +1,4 @@
 import type { SessionConfig } from "vinxi/http";
-import { env } from "~/env/server";
 import { AUTH_CONFIG, expiryToSeconds } from "~/config";
 
 /**
@@ -21,17 +20,58 @@ export interface SessionData {
   rememberMe: boolean;
 }
 
+/**
+ * Get session password directly from process.env
+ * This avoids any bundler-time substitution issues with the validated env object
+ */
+function getSessionPassword(): string {
+  // Read directly from process.env at runtime, not from bundled env object
+  const password = process.env.JWT_SECRET_KEY;
+  if (!password || password.trim() === "") {
+    console.error(
+      `[SessionConfig] JWT_SECRET_KEY missing from process.env! Keys available:`,
+      Object.keys(process.env)
+        .filter((k) => k.includes("JWT") || k.includes("SECRET"))
+        .join(", ") || "none matching JWT/SECRET"
+    );
+    throw new Error(
+      `JWT_SECRET_KEY is empty at runtime. Ensure it is set as a runtime environment variable in Vercel (not just build-time).`
+    );
+  }
+  return password;
+}
+
+/**
+ * Get session config with runtime password validation
+ * Returns a fresh config each time to ensure env vars are read at call time,
+ * not at module load time (important for serverless cold starts)
+ */
+export function getSessionConfig(): SessionConfig {
+  return {
+    password: getSessionPassword(),
+    name: "session",
+    cookie: {
+      httpOnly: true,
+      secure: process.env.NODE_ENV === "production",
+      sameSite: "lax",
+      path: "/"
+    }
+  };
+}
+
 /**
  * Vinxi session configuration
- * Uses iron-session style password-based encryption
+ * Using a getter ensures password is evaluated at access time, not module load time
  */
 export const sessionConfig: SessionConfig = {
-  password: env.JWT_SECRET_KEY,
+  get password() {
+    return getSessionPassword();
+  },
   name: "session",
   cookie: {
     httpOnly: true,
-    secure: env.NODE_ENV === "production",
-    sameSite: "lax", // Allow cookies on top-level navigation (OAuth/email redirects) for WebKit compatibility
+    secure: process.env.NODE_ENV === "production",
+    sameSite: "lax",
     path: "/"
   }
 };

src/server/session-helpers.ts

@@ -13,7 +13,7 @@ import { env } from "~/env/server";
 import { AUTH_CONFIG, expiryToSeconds, CACHE_CONFIG } from "~/config";
 import { logAuditEvent } from "./audit";
 import type { SessionData } from "./session-config";
-import { sessionConfig } from "./session-config";
+import { sessionConfig, getSessionConfig } from "./session-config";
 import { getDeviceInfo } from "./device-utils";
 import { cache } from "./cache";
 
@@ -213,8 +213,10 @@ export async function createAuthSession(
   });
 
   // Update Vinxi session with dynamic maxAge based on rememberMe
+  // Use getSessionConfig() to ensure password is read at runtime
+  const baseConfig = getSessionConfig();
   const configWithMaxAge = {
-    ...sessionConfig,
+    ...baseConfig,
     maxAge: rememberMe
       ? expiryToSeconds(AUTH_CONFIG.REFRESH_TOKEN_EXPIRY_LONG)
       : undefined // Session cookie (expires on browser close)