fix(update/windows): don't return _UvResult on Windows (subprocess argv crash) (#39820)

PR #39780 made ensure_uv() return a _UvResult — a str subclass whose
__iter__ yields (path, fresh_bootstrap) so old `uv_bin, fresh = ensure_uv()`
call sites survive the update boundary. That trick is unsafe on Windows.

The dependency installer passes uv straight into the command list
(`[uv_bin, "pip", "install", ...]`). On Windows, subprocess serializes argv
via subprocess.list2cmdline, which iterates every entry *as a string*
(`for c in arg`). Because _UvResult overrides __iter__, that iteration yields
(path, fresh_bootstrap) instead of characters, injecting the bool into the
command line and crashing the first update with:

    TypeError: sequence item 1: expected str instance, bool found

This bites the common single-assignment caller (`uv_bin = ensure_uv()`) on
its first update after #39780: the freshly pulled _UvResult flows into the
old in-memory call site and into the argv. Reported in the field on a
~10-commits-behind Windows install.

A single return value cannot satisfy both legacy 2-target unpacking and
Windows char-iteration — both use the iterator protocol with contradictory
results. So gate the wrapper to POSIX: Windows returns a plain str/None
(the historical, subprocess-safe contract). POSIX keeps _UvResult and the
#39780 update-boundary fix.

Tests: list2cmdline canary proving _UvResult breaks Windows, plus Windows
returns-plain-str and POSIX dual-contract coverage.

hermes_cli/managed_uv.py

@@ -72,6 +72,9 @@ class _UvResult(str):
     Missing uv is the empty string (falsy) instead of ``None`` so legacy
     2-target call sites can still unpack a failure without raising, while
     ``if not uv_bin`` keeps working for single-value callers.
+
+    POSIX only. This wrapper is **never** returned on Windows — see
+    ``ensure_uv()`` for why the ``__iter__`` override is unsafe there.
     """
 
     fresh_bootstrap: bool
@@ -88,17 +91,11 @@ class _UvResult(str):
         return iter(((str(self) or None), self.fresh_bootstrap))
 
 
-def ensure_uv() -> "_UvResult":
-    """Return the managed uv path, installing it first if necessary.
-
-    Returns a :class:`_UvResult` (a ``str`` subclass) that is both usable
-    directly as the path and unpackable as ``(path, fresh_bootstrap)`` for
-    older call sites. On failure the result is falsy (``""``) — never raises —
-    so callers can fall back to pip gracefully.
-    """
+def _ensure_uv_path() -> Optional[str]:
+    """Resolve the managed uv path, installing it if necessary (plain ``str``/``None``)."""
     existing = resolve_uv()
     if existing:
-        return _UvResult(existing)
+        return existing
 
     target = managed_uv_path()
     target.parent.mkdir(parents=True, exist_ok=True)
@@ -110,7 +107,7 @@ def ensure_uv() -> "_UvResult":
     except Exception as exc:
         logger.warning("Managed uv install failed: %s", exc)
         print(f"  ✗ Failed to install managed uv: {exc}")
-        return _UvResult(None)
+        return None
 
     # Verify
     result = resolve_uv()
@@ -124,6 +121,37 @@ def ensure_uv() -> "_UvResult":
         print(f"  ✓ Managed uv installed ({version})")
     else:
         print("  ✗ Managed uv install appeared to succeed but binary not found")
+    return result
+
+
+def ensure_uv():
+    """Return the managed uv path, installing it first if necessary.
+
+    On **POSIX** the result is a :class:`_UvResult` (a ``str`` subclass) that is
+    both usable directly as the path *and* unpackable as
+    ``(path, fresh_bootstrap)`` for older call sites parked on a 2-tuple
+    release — see :class:`_UvResult` for the update-boundary rationale.
+
+    On **Windows** we deliberately return a plain ``str``/``None`` instead.
+    ``subprocess`` there serializes the argv via ``subprocess.list2cmdline``,
+    which iterates every entry *as a string* (``for c in arg``). The dependency
+    installer passes uv straight into the command list (``[uv_bin, "pip", ...]``),
+    so a ``_UvResult`` — whose ``__iter__`` yields ``(path, fresh_bootstrap)``
+    rather than characters — would inject the bool into the command line and
+    crash the install with ``TypeError: sequence item 1: expected str instance,
+    bool found``. A plain ``str`` matches the historical Windows contract and is
+    subprocess-safe. (A single value cannot satisfy both 2-target unpacking and
+    Windows char-iteration: both use the iterator protocol, with contradictory
+    results.)
+
+    On failure the result is falsy — never raises — so callers can fall back to
+    pip gracefully.
+    """
+    result = _ensure_uv_path()
+    if platform.system() == "Windows":
+        # See docstring: a str subclass with an overridden __iter__ is unsafe as
+        # a Windows subprocess argument. Hand back the plain path (or None).
+        return result
     return _UvResult(result)
 
 

tests/hermes_cli/test_managed_uv.py

@@ -105,7 +105,7 @@ class TestEnsureUv:
 
 class TestEnsureUvUpdateBoundary:
     """``ensure_uv()`` must answer to both the single-value and the legacy
-    ``(path, fresh_bootstrap)`` call conventions.
+    ``(path, fresh_bootstrap)`` call conventions — **on POSIX**.
 
     ``hermes update`` runs the call site from the old, already-imported
     ``hermes_cli.main`` against the freshly pulled ``managed_uv``. A release
@@ -113,14 +113,19 @@ class TestEnsureUvUpdateBoundary:
     against the single-value module; the path is an iterable ``str`` so the
     2-target unpack walked its characters and raised
     ``ValueError: too many values to unpack (expected 2)`` (root cause behind
-    PR #39763), or ``TypeError`` on the ``None`` failure path. The result must
-    therefore be usable as a bare path *and* unpackable as a 2-tuple, in both
-    the success and failure cases.
+    PR #39763), or ``TypeError`` on the ``None`` failure path. On POSIX the
+    result must therefore be usable as a bare path *and* unpackable as a
+    2-tuple, in both the success and failure cases.
+
+    The dual contract is intentionally **not** offered on Windows — see
+    ``TestEnsureUvWindowsSafe`` for why — so these tests pin ``platform.system``
+    to a POSIX value.
     """
 
     def test_success_usable_as_single_value(self, tmp_path):
         _make_executable(tmp_path / "bin" / "uv")
-        with patch("hermes_cli.managed_uv.get_hermes_home", return_value=tmp_path):
+        with patch("hermes_cli.managed_uv.get_hermes_home", return_value=tmp_path), \
+             patch("hermes_cli.managed_uv.platform.system", return_value="Linux"):
             from hermes_cli.managed_uv import ensure_uv
             uv_bin = ensure_uv()
             assert uv_bin == str(tmp_path / "bin" / "uv")
@@ -128,7 +133,8 @@ class TestEnsureUvUpdateBoundary:
 
     def test_success_unpacks_as_legacy_two_tuple(self, tmp_path):
         _make_executable(tmp_path / "bin" / "uv")
-        with patch("hermes_cli.managed_uv.get_hermes_home", return_value=tmp_path):
+        with patch("hermes_cli.managed_uv.get_hermes_home", return_value=tmp_path), \
+             patch("hermes_cli.managed_uv.platform.system", return_value="Linux"):
             from hermes_cli.managed_uv import ensure_uv
             uv_bin, fresh = ensure_uv()  # old: uv_bin, fresh_bootstrap = ensure_uv()
             assert uv_bin == str(tmp_path / "bin" / "uv")
@@ -136,6 +142,7 @@ class TestEnsureUvUpdateBoundary:
 
     def test_failure_unpacks_without_raising(self, tmp_path):
         with patch("hermes_cli.managed_uv.get_hermes_home", return_value=tmp_path), \
+             patch("hermes_cli.managed_uv.platform.system", return_value="Linux"), \
              patch("hermes_cli.managed_uv._install_uv", side_effect=RuntimeError("network down")):
             from hermes_cli.managed_uv import ensure_uv
             uv_bin, fresh = ensure_uv()
@@ -143,6 +150,52 @@ class TestEnsureUvUpdateBoundary:
             assert fresh is False
 
 
+class TestEnsureUvWindowsSafe:
+    """On Windows ``ensure_uv()`` must return a plain ``str``/``None``.
+
+    ``subprocess`` on Windows serializes argv through
+    ``subprocess.list2cmdline``, which iterates every entry *as a string*
+    (``for c in arg``). The dependency installer feeds uv straight into the
+    command list (``[uv_bin, "pip", "install", ...]``). A ``str`` subclass
+    whose ``__iter__`` yields ``(path, fresh_bootstrap)`` instead of characters
+    therefore injects the bool into the command line and crashes the install
+    with ``TypeError: sequence item 1: expected str instance, bool found``
+    (a real field report on a 10-commits-behind Windows install). A single
+    return value cannot serve both the legacy 2-tuple unpack and Windows
+    char-iteration — both use the iterator protocol — so Windows opts out of
+    the wrapper entirely.
+    """
+
+    def test_uvresult_would_break_windows_list2cmdline(self):
+        # Canary: this is *why* the wrapper is gated off Windows. If a future
+        # change makes _UvResult char-iterable (and thus list2cmdline-safe),
+        # the gate may be revisited.
+        import subprocess
+        from hermes_cli.managed_uv import _UvResult
+        with pytest.raises(TypeError):
+            subprocess.list2cmdline([_UvResult("C:\\hermes\\uv.exe"), "pip"])
+
+    def test_windows_returns_plain_str_safe_for_subprocess(self, tmp_path):
+        import subprocess
+        # On (mocked) Windows the managed binary is uv.exe.
+        _make_executable(tmp_path / "bin" / "uv.exe")
+        with patch("hermes_cli.managed_uv.get_hermes_home", return_value=tmp_path), \
+             patch("hermes_cli.managed_uv.platform.system", return_value="Windows"):
+            from hermes_cli.managed_uv import _UvResult, ensure_uv
+            uv_bin = ensure_uv()
+            assert type(uv_bin) is str and not isinstance(uv_bin, _UvResult)
+            # The exact operation that crashed in the field must now succeed.
+            cmdline = subprocess.list2cmdline([uv_bin, "pip", "install", "-e", "."])
+            assert "pip" in cmdline and "install" in cmdline
+
+    def test_windows_failure_returns_none(self, tmp_path):
+        with patch("hermes_cli.managed_uv.get_hermes_home", return_value=tmp_path), \
+             patch("hermes_cli.managed_uv.platform.system", return_value="Windows"), \
+             patch("hermes_cli.managed_uv._install_uv", side_effect=RuntimeError("network down")):
+            from hermes_cli.managed_uv import ensure_uv
+            assert ensure_uv() is None
+
+
 # ---------------------------------------------------------------------------
 # update_managed_uv
 # ---------------------------------------------------------------------------