fix: resolve E2E server startup issues in pre-push hook

- Create dedicated playwright.config.pre-push.ts for pre-push testing
- Fix Rspack module resolution panics by properly managing server lifecycle
- Use manual server management with pnpm serve:all for built files
- Add proper server readiness checks and cleanup
- Reduce to essential browsers (Chromium, Firefox, Mobile) for pre-push
- Remove CI=true flag that was causing serve:all to run prematurely

This resolves the "No module found" Rspack panics and ensures E2E tests
run against properly built and served files.

🤖 Generated with [Claude Code](https://claude.ai/code)

Co-Authored-By: Claude <[email protected]>

Author: jonphipps

.husky/pre-push-optimized

@@ -65,20 +65,32 @@ if [ "$BRANCH" = "main" ] || [ "$BRANCH" = "dev" ]; then
 
   # 4. Only run E2E if portal is affected
   if echo "$AFFECTED_PROJECTS" | grep -q "portal"; then
-    echo "🌐 Portal affected - running multi-browser E2E tests..."
-    # Set CI=true to use serve:all (built files) instead of start:all (dev servers)
-    echo "🧪 Testing on Chromium..."
-    CI=true npx playwright test --project=chromium || {
-      echo "⚠️  Chromium E2E tests failed but continuing"
-    }
-    echo "🧪 Testing on Firefox..."
-    CI=true npx playwright test --project=firefox || {
-      echo "⚠️  Firefox E2E tests failed but continuing"
-    }
-    echo "🧪 Testing on Mobile Chrome..."
-    CI=true npx playwright test --project="Mobile Chrome" || {
-      echo "⚠️  Mobile Chrome E2E tests failed but continuing"
-    }
+    echo "🌐 Portal affected - running E2E tests against built files..."
+    
+    # Start servers for built files
+    echo "🚀 Starting servers for built files..."
+    pnpm serve:all &
+    SERVER_PID=$!
+    
+    # Wait for servers to be ready
+    echo "⏳ Waiting for servers to start..."
+    sleep 10
+    
+    # Check if portal is accessible
+    if curl -s http://localhost:3000 > /dev/null; then
+      echo "✅ Servers ready, running E2E tests..."
+      npx playwright test --config=playwright.config.pre-push.ts || {
+        echo "⚠️  E2E tests failed but continuing (non-blocking for protected branches)"
+      }
+    else
+      echo "❌ Servers failed to start, skipping E2E tests"
+    fi
+    
+    # Cleanup servers
+    echo "🧹 Stopping servers..."
+    kill $SERVER_PID 2>/dev/null || true
+    pnpm stop:all || true
+    
   else
     echo "📝 Portal not affected - skipping E2E tests"
   fi

playwright.config.pre-push.ts

@@ -0,0 +1,42 @@
+import { defineConfig, devices } from '@playwright/test';
+
+/**
+ * Pre-push specific Playwright configuration
+ * Tests against built files served via docusaurus serve
+ */
+export default defineConfig({
+  testDir: './e2e',
+  fullyParallel: false, // Sequential for pre-push reliability
+  forbidOnly: true,
+  retries: 1, // One retry for flaky tests
+  workers: 1, // Single worker for stability
+  reporter: [
+    ['list'],
+    ['json', { outputFile: 'test-results/e2e-pre-push-results.json' }]
+  ],
+  use: {
+    baseURL: 'http://localhost:3000',
+    trace: 'on-first-retry',
+    screenshot: 'only-on-failure',
+    video: 'retain-on-failure',
+  },
+
+  /* Test only essential browsers for pre-push */
+  projects: [
+    {
+      name: 'chromium',
+      use: { ...devices['Desktop Chrome'] },
+    },
+    {
+      name: 'firefox', 
+      use: { ...devices['Desktop Firefox'] },
+    },
+    {
+      name: 'mobile',
+      use: { ...devices['Pixel 5'] },
+    }
+  ],
+
+  /* No automatic server - we'll manage it manually in pre-push hook */
+  // webServer: undefined,
+});