fix(health): handle errors that cannot convert to strings

CHANGES.md

@@ -1,5 +1,10 @@
 # Changelog
 
+## Unreleased
+
+- Health reports and responder fallbacks remain available when a rejected value
+  cannot convert to a string. The error uses generic text without private fields.
+
 ## 0.1.2
 
 - Every hosting package (`fly`, `koyeb`, `railway`, `vercel`, `cloudflare`)

packages/health/src/errors.ts

@@ -50,5 +50,10 @@ export function resolveFormatError(
 }
 
 export function toError<T>(value: T): Error {
-  return value instanceof Error ? value : new Error(String(value));
+  if (value instanceof Error) return value;
+  try {
+    return new Error(String(value));
+  } catch {
+    return new Error("failed");
+  }
 }

packages/health/src/responder.test.ts

@@ -119,6 +119,28 @@ test("createHealthResponder() reports a rejected extend and a thrown onError", a
   assert.equal(rendered.body.status, "ok");
 });
 
+test("createHealthResponder() serves the report when an extend rejection cannot become a string", async () => {
+  const errors: Error[] = [];
+  const responder = createHealthResponder<Ctx>({
+    probes: [failingProbe("a", true)],
+    extend: () => Promise.reject({ toString: 0, code: "PRIVATE_FAILURE" }),
+    onError: (error) => errors.push(error),
+  });
+  const rendered = await responder.respond({});
+  assert.equal(rendered.status, 503);
+  assert.equal(rendered.body.status, "unhealthy");
+  assert.equal(rendered.body.checks?.[0].status, "failed");
+  assert.deepEqual(Object.keys(rendered.body).sort(), [
+    "checkedAt",
+    "checks",
+    "latencyMs",
+    "status",
+  ]);
+  assert.equal(errors.length, 1);
+  assert.ok(errors[0] instanceof Error);
+  assert.doesNotMatch(errors[0].message, /PRIVATE_FAILURE/);
+});
+
 test("createHealthResponder() treats a throwing exposeChecks as false", async () => {
   const seen: Error[] = [];
   const responder = createHealthResponder<Ctx>({
@@ -137,6 +159,29 @@ test("createHealthResponder() treats a throwing exposeChecks as false", async ()
   assert.equal(seen[0]?.message, "auth down");
 });
 
+test("createHealthResponder() hides details when an exposeChecks rejection cannot become a string", async () => {
+  const errors: Error[] = [];
+  let extended = false;
+  const responder = createHealthResponder<Ctx>({
+    probes: [failingProbe("a", true)],
+    exposeChecks: () =>
+      Promise.reject({ toString: 0, code: "PRIVATE_FAILURE" }),
+    extend: () => {
+      extended = true;
+      return { secret: "private" };
+    },
+    onError: (error) => errors.push(error),
+  });
+  const rendered = await responder.respond({});
+  assert.equal(rendered.status, 503);
+  assert.equal(rendered.body.status, "unhealthy");
+  assert.deepEqual(Object.keys(rendered.body).sort(), ["checkedAt", "status"]);
+  assert.equal(extended, false);
+  assert.equal(errors.length, 1);
+  assert.ok(errors[0] instanceof Error);
+  assert.doesNotMatch(errors[0].message, /PRIVATE_FAILURE/);
+});
+
 test("createHealthResponder() passes the context to onError", async () => {
   let seen: Ctx | undefined;
   const responder = createHealthResponder<Ctx>({

packages/health/src/run.test.ts

@@ -114,6 +114,19 @@ test("runProbes() passes real errors to formatError", async () => {
   assert.equal(report.checks[1].error, "E: raw");
 });
 
+test("runProbes() reports critical rejections that cannot become strings", async () => {
+  const report = await runProbes([{
+    name: "a",
+    critical: true,
+    run: () => Promise.reject({ toString: 0, code: "PRIVATE_FAILURE" }),
+  }], { formatError: "message" });
+  assert.equal(report.status, "unhealthy");
+  assert.equal(report.checks[0].status, "failed");
+  assert.equal(report.checks[0].critical, true);
+  assert.equal(typeof report.checks[0].error, "string");
+  assert.doesNotMatch(JSON.stringify(report), /PRIVATE_FAILURE/);
+});
+
 test("runProbes() times out and aborts the signal", async () => {
   const report = await runProbes([hanging("a", true)]);
   assert.equal(report.status, "unhealthy");