feat: Add conditional MAIL_HOST validation, lazy-load mailer, and update Gitea workflow to use vars for mail and Sentry environment variables.

lib/mail/mailer.test.ts

@@ -0,0 +1,59 @@
+import { describe, it, expect, vi, beforeEach } from 'vitest';
+import { sendEmail } from './mailer';
+import { config } from '../config';
+
+// Mock getServerAppServices to avoid full app initialization
+vi.mock('@/lib/services/create-services.server', () => ({
+  getServerAppServices: () => ({
+    logger: {
+      child: () => ({
+        info: vi.fn(),
+        error: vi.fn(),
+        warn: vi.fn(),
+      }),
+    },
+  }),
+}));
+
+// Mock config
+vi.mock('../config', () => ({
+  config: {
+    mail: {
+      host: 'smtp.example.com',
+      port: 587,
+      user: 'user',
+      pass: 'pass',
+      from: 'from@example.com',
+      recipients: ['to@example.com'],
+    },
+  },
+  getConfig: vi.fn(),
+}));
+
+describe('mailer', () => {
+  beforeEach(() => {
+    vi.clearAllMocks();
+  });
+
+  describe('sendEmail', () => {
+    it('should throw error if MAIL_HOST is missing', async () => {
+      // Temporarily nullify host
+      const originalHost = config.mail.host;
+      (config.mail as any).host = '';
+
+      const result = await sendEmail({
+        subject: 'Test',
+        html: '<p>Test</p>',
+      });
+
+      expect(result.success).toBe(false);
+      expect((result.error as Error).message).toContain('MAIL_HOST is not configured');
+
+      // Restore host
+      (config.mail as any).host = originalHost;
+    });
+
+    // In a real environment, we'd mock nodemailer, but for now we focus on the validation logic
+    // we added. Full SMTP integration tests are usually out of scope for unit tests.
+  });
+});

lib/mail/mailer.ts

@@ -3,15 +3,27 @@ import { getServerAppServices } from '@/lib/services/create-services.server';
 import { config } from '../config';
 import { ReactElement } from 'react';
 
-const transporter = nodemailer.createTransport({
-  host: config.mail.host,
-  port: config.mail.port,
-  secure: config.mail.port === 465,
-  auth: {
-    user: config.mail.user,
-    pass: config.mail.pass,
-  },
-});
+let transporterInstance: nodemailer.Transporter | null = null;
+
+function getTransporter() {
+  if (transporterInstance) return transporterInstance;
+
+  if (!config.mail.host) {
+    throw new Error('MAIL_HOST is not configured. Please check your environment variables.');
+  }
+
+  transporterInstance = nodemailer.createTransport({
+    host: config.mail.host,
+    port: config.mail.port,
+    secure: config.mail.port === 465,
+    auth: {
+      user: config.mail.user,
+      pass: config.mail.pass,
+    },
+  });
+
+  return transporterInstance;
+}
 
 interface SendEmailOptions {
   to?: string | string[];
@@ -32,7 +44,7 @@ export async function sendEmail({ to, subject, html }: SendEmailOptions) {
   const logger = getServerAppServices().logger.child({ component: 'mailer' });
 
   try {
-    const info = await transporter.sendMail(mailOptions);
+    const info = await getTransporter().sendMail(mailOptions);
     logger.info('Email sent successfully', { messageId: info.messageId, subject, recipients });
     return { success: true, messageId: info.messageId };
   } catch (error) {