fix(setup): initialize secrets crypto for env-var security option

[zmanian]

Summary

Closes #666.

• Initialize secrets_crypto when the user picks "Environment variable" in the setup wizard's security step, so subsequent API key saves work
• Auto-write SECRETS_MASTER_KEY to ~/.ironclaw/.env via write_bootstrap_env so the key persists across restarts
• Use inject_single_var (thread-safe overlay) instead of unsafe set_var
• Fix misleading message: clarify that only .env files work (not shell profiles)

Root cause

Option 1 (env var) in step_security() generated the master key and printed it, but never set self.secrets_crypto. This left it None, causing init_secrets_context() to fail when trying to encrypt API keys in later wizard steps.

Test plan

• test_env_var_security_initializes_crypto -- verifies generated key produces valid SecretsCrypto
• cargo clippy --all --all-features -- zero warnings
• cargo test --all-features -- all lib tests pass

Generated with Claude Code

[gemini-code-assist]

Summary of Changes

Hello, I'm Gemini Code Assist¹! I'm currently reviewing this pull request and will post my feedback shortly. In the meantime, here's a summary to help you and other reviewers quickly get up to speed!

This pull request addresses a critical bug in the setup wizard where selecting the "Environment variable" option for master key storage failed to properly initialize the secrets cryptography context. This oversight prevented subsequent steps, such as API key storage, from functioning correctly. The changes ensure that the crypto context is immediately available, the generated master key is persistently stored in the .env file, and user guidance is improved, leading to a more robust and user-friendly setup experience.

Highlights

• Secrets Crypto Initialization: Initialized secrets_crypto when the "Environment variable" security option is selected in the setup wizard, resolving issues with subsequent API key encryption.
• Master Key Persistence: Implemented automatic persistence of the SECRETS_MASTER_KEY to ~/.ironclaw/.env using write_bootstrap_env for restart durability.
• Environment Variable Handling: Switched to inject_single_var for setting environment variables, ensuring thread-safe overlay behavior.
• User Messaging Improvement: Clarified user messaging regarding the use of .env files for master key storage, removing ambiguity about shell profiles.
• Settings Structure Update: Introduced a new secrets_master_key_hex field in the Settings struct to store the generated master key for persistence.
• Regression Test: Added a regression test, test_env_var_security_initializes_crypto, to validate the fix for secrets crypto initialization.

Changelog

• src/settings.rs
  • Added secrets_master_key_hex field to Settings struct.
• src/setup/wizard.rs
  • Modified the environment variable security option logic to initialize secrets_crypto and inject the master key.
  • Updated the write_bootstrap_env function to persist the SECRETS_MASTER_KEY to the .env file.
  • Improved user messaging for the environment variable security option.
  • Added test_env_var_security_initializes_crypto regression test.

Activity

• Verified test_env_var_security_initializes_crypto to ensure the fix.
• Confirmed cargo clippy --all --all-features passed with zero warnings.
• Ensured cargo test --all-features passed all library tests.

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[gemini-code-assist]

Code Review

This pull request correctly fixes a bug where the secrets crypto context was not initialized when using the environment variable security option during setup. The changes ensure that secrets_crypto is properly instantiated, allowing subsequent API key encryption to succeed. The master key is also now correctly persisted to ~/.ironclaw/.env for future runs. Additionally, the code is improved by replacing an unsafe std::env::set_var call with a thread-safe equivalent. The new test case effectively validates the fix. The changes are well-implemented and address the issue thoroughly.

_{Note: Security Review did not run due to the size of the PR.}