chore: add diagnostic rewrite and automated asset smoke tests

.gitea/workflows/deploy.yml

@@ -154,6 +154,30 @@ jobs:
         run: |
           echo "${{ secrets.REGISTRY_PASS }}" | docker login registry.infra.mintel.me -u "${{ secrets.REGISTRY_USER }}" --password-stdin
 
+      - name: 🧹 Nuclear Runner Cleanup
+        run: |
+          echo "Disk space before nuclear prune:"
+          df -h
+          
+          # Massive cleanup of pre-installed runner software to free up ~5GB+
+          # These are standard on VM-based runners and often unnecessary
+          sudo rm -rf /usr/share/dotnet || true
+          sudo rm -rf /usr/local/lib/android || true
+          sudo rm -rf /opt/ghc || true
+          sudo rm -rf /opt/hostedtoolcache/CodeQL || true
+          
+          # Comprehensive Docker purge
+          docker system prune -af --volumes
+          docker builder prune -af
+          docker buildx prune -af
+          
+          # Clean temp build artifacts
+          rm -rf /tmp/docker-actions-toolkit-* || true
+          
+          echo "Disk space after nuclear prune:"
+          df -h
+        continue-on-error: true
+
       - name: 🏗️ Build and Push
         uses: docker/build-push-action@v5
         with:
@@ -176,8 +200,9 @@ jobs:
             PAYLOAD_SECRET=${{ secrets.PAYLOAD_SECRET || 'secret' }}
             BUILD_ID=${{ github.sha }}
           tags: registry.infra.mintel.me/mintel/mintel.me:${{ needs.prepare.outputs.image_tag }}
+          # Temporarily disable registry cache export to save runner disk/bandwidth
           cache-from: type=registry,ref=registry.infra.mintel.me/mintel/mintel.me:buildcache-${{ needs.prepare.outputs.target }}
-          cache-to: type=registry,ref=registry.infra.mintel.me/mintel/mintel.me:buildcache-${{ needs.prepare.outputs.target }},mode=max
+          # cache-to: type=registry,ref=registry.infra.mintel.me/mintel/mintel.me:buildcache-${{ needs.prepare.outputs.target }},mode=max
           secrets: |
             NPM_TOKEN=${{ secrets.NPM_TOKEN }}
 
@@ -432,6 +457,7 @@ jobs:
       - name: 🌐 Check Production URL
         shell: sh
         run: |
+          apk add --no-cache curl
           # Wait longer (up to 2 minutes) for Next.js to fully prime
           COUNT=0
           MAX=24
@@ -454,17 +480,44 @@ jobs:
             exit 1
           fi
 
-      - name: 🌐 Check Case Study Assets
+      - name: 🌐 Check Case Study Assets and Rewrites
         shell: sh
         run: |
-          URL="${{ needs.prepare.outputs.next_public_url }}/case-studies/klz-cables"
+          BASE_URL="${{ needs.prepare.outputs.next_public_url }}"
-          echo "Verifying case study $URL..."
+          
-          STATUS=$(curl -s -o /dev/null -w "%{http_code}" "$URL")
+          echo "Verifying diagnostic rewrite..."
+          STATUS=$(curl -s -L -o /dev/null -w "%{http_code}" "$BASE_URL/robots-test")
+          if [ "$STATUS" != "200" ]; then
+            echo "❌ Diagnostic rewrite /robots-test failed! (Status: $STATUS)"
+            exit 1
+          fi
+          echo "✅ Diagnostic rewrite OK"
+          
+          echo "Verifying case study page..."
+          STATUS=$(curl -s -o /dev/null -w "%{http_code}" "$BASE_URL/case-studies/klz-cables")
           if [ "$STATUS" != "200" ]; then
             echo "❌ Case study page failed! (Status: $STATUS)"
             exit 1
           fi
-          echo "✅ Case study page is UP"
+          echo "✅ Case study page UP"
+          
+          echo "Verifying breeze CSS (root path)..."
+          CSS_PATH="/assets/klz-cables.com/wp-content/cache/breeze-minification/css/breeze_klz-cables-com-1-10895.css"
+          STATUS=$(curl -s -o /dev/null -w "%{http_code}" "$BASE_URL$CSS_PATH")
+          if [ "$STATUS" != "200" ]; then
+            echo "❌ Root asset path failed! (Status: $STATUS)"
+            exit 1
+          fi
+          echo "✅ Root asset path OK"
+          
+          echo "Verifying breeze CSS (relative path from case-study)..."
+          REL_CSS_PATH="/case-studies/assets/klz-cables.com/wp-content/cache/breeze-minification/css/breeze_klz-cables-com-1-10895.css"
+          STATUS=$(curl -s -o /dev/null -w "%{http_code}" "$BASE_URL$REL_CSS_PATH")
+          if [ "$STATUS" != "200" ]; then
+            echo "❌ Relative asset path failed! (Status: $STATUS)"
+            exit 1
+          fi
+          echo "✅ Relative asset path OK"
 
   # ──────────────────────────────────────────────────────────────────────────────
   # JOB 6: Notifications

Dockerfile

@@ -39,6 +39,9 @@ ENV CI=true
 # Copy manifest files specifically for better layer caching
 COPY pnpm-lock.yaml pnpm-workspace.yaml package.json .npmrc* ./
 COPY apps/web/package.json ./apps/web/package.json
+# Install build dependencies for native modules (like canvas)
+RUN apk add --no-cache python3 make g++ pkgconfig pixman-dev cairo-dev pango-dev libjpeg-turbo-dev giflib-dev librsvg-dev
+
 # Copy sibling monorepo for linked dependencies (cloned during CI)
 # Placing it inside /app so relative links like ../../_at-mintel resolve correctly!
 COPY _at-mintel* /app/_at-mintel/
@@ -72,17 +75,14 @@ WORKDIR /app
 
 # Copy standalone output and static files (Monorepo paths)
 # Note: Base image already handles the non-root user and basic env
-COPY --from=builder /app/apps/web/public ./apps/web/public
+COPY --from=builder --chown=1001:65533 /app/apps/web/public ./apps/web/public
-COPY --from=builder /app/apps/web/.next/standalone ./
+COPY --from=builder --chown=1001:65533 /app/apps/web/.next/standalone ./
-COPY --from=builder /app/apps/web/.next/static ./apps/web/.next/static
+COPY --from=builder --chown=1001:65533 /app/apps/web/.next/static ./apps/web/.next/static
 
 # Explicitly copy Payload dynamically generated importMap.js excluded by Standalone tracing
-COPY --from=builder /app/apps/web/app/(payload)/admin/importMap.js ./apps/web/app/(payload)/admin/importMap.js
+COPY --from=builder --chown=1001:65533 /app/apps/web/app/(payload)/admin/importMap.js ./apps/web/app/(payload)/admin/importMap.js
 
 # Fix permissions for the non-root user (Standard uid/gid from base image)
-# We do this as root before switching users
-USER root
-RUN chown -R 1001:65533 /app
 USER nextjs
 
 # Start from the app directory to ensure references solve correctly

apps/web/next.config.mjs

@@ -38,22 +38,41 @@ const nextConfig = {
     ],
   },
   async rewrites() {
-    return [
+    return {
-      // Umami proxy rewrite handled in app/stats/api/send/route.ts
+      beforeFiles: [
-      // Sentry relay handled in app/errors/api/relay/route.ts
+        // Assets requested from root
-      {
+        {
-        source: '/assets/:path*',
+          source: '/assets/:path*',
-        destination: '/showcase/klz-cables.com/assets/:path*',
+          destination: '/showcase/klz-cables.com/assets/:path*',
-      },
+        },
-      {
+        {
-        source: '/wp-content/:path*',
+          source: '/wp-content/:path*',
-        destination: '/showcase/klz-cables.com/assets/klz-cables.com/wp-content/:path*',
+          destination: '/showcase/klz-cables.com/assets/klz-cables.com/wp-content/:path*',
-      },
+        },
-      {
+        {
-        source: '/wp-includes/:path*',
+          source: '/wp-includes/:path*',
-        destination: '/showcase/klz-cables.com/assets/klz-cables.com/wp-includes/:path*',
+          destination: '/showcase/klz-cables.com/assets/klz-cables.com/wp-includes/:path*',
-      },
+        },
-    ];
+        // Assets requested relatively from case-studies/work/blog subpages
+        {
+          source: '/:folder(case-studies|work|blog)/assets/:path*',
+          destination: '/showcase/klz-cables.com/assets/:path*',
+        },
+        {
+          source: '/:folder(case-studies|work|blog)/wp-content/:path*',
+          destination: '/showcase/klz-cables.com/assets/klz-cables.com/wp-content/:path*',
+        },
+        {
+          source: '/:folder(case-studies|work|blog)/wp-includes/:path*',
+          destination: '/showcase/klz-cables.com/assets/klz-cables.com/wp-includes/:path*',
+        },
+        // Diagnostic rule
+        {
+          source: '/robots-test',
+          destination: '/robots.txt',
+        },
+      ],
+    };
   },
   async redirects() {
     return [

apps/web/src/components/ContactForm.tsx

@@ -246,6 +246,7 @@ export function ContactForm({
         onBack={() => setFlow("discovery")} // Can keep, but won't be seen if we hide button
         onSubmit={() => handleSubmit()}
         isSubmitting={isSubmitting}
+        error={error}
       />
     );
   }

apps/web/src/components/ContactForm/DirectMessageFlow.tsx

@@ -35,6 +35,7 @@ interface DirectMessageFlowProps {
   onBack: () => void;
   onSubmit: () => void;
   isSubmitting: boolean;
+  error?: string | null;
 }
 
 export const DirectMessageFlow = ({
@@ -57,10 +58,32 @@ export const DirectMessageFlow = ({
   onBack,
   onSubmit,
   isSubmitting,
+  error,
 }: DirectMessageFlowProps) => {
   return (
     <div className="w-full max-w-3xl mx-auto px-4 py-12">
       <div className="space-y-12">
+        {error && (
+          <Reveal width="100%" delay={0.1}>
+            <div className="bg-red-50 border border-red-100 rounded-2xl p-6 flex items-start gap-4 mb-8">
+              <div className="p-2 bg-red-100 rounded-lg text-red-600">
+                <Mail size={20} className="animate-pulse" />
+              </div>
+              <div className="space-y-1">
+                <h3 className="text-red-900 font-bold text-sm uppercase tracking-wider">
+                  Übertragungsfehler
+                </h3>
+                <p className="text-red-700/80 font-medium text-base">
+                  {error}
+                </p>
+                <div className="mt-2 text-[10px] font-mono text-red-400 uppercase tracking-widest">
+                  Status: FEHLER_BEI_SEQUENZ_INIT
+                </div>
+              </div>
+            </div>
+          </Reveal>
+        )}
+
         <Reveal width="100%" delay={0.2}>
           <div className="space-y-4">
             <span className="text-[10px] font-mono text-green-600 uppercase tracking-[0.3em] font-bold">

apps/web/src/lib/mail/mailer.ts

@@ -45,11 +45,23 @@ export async function sendEmail({
   subject,
   html,
 }: SendEmailOptions) {
-  const recipients = to || env.MAIL_RECIPIENTS;
+  let recipients = to || env.MAIL_RECIPIENTS;
+  let from = env.MAIL_FROM;
+
+  if (!from) {
+    from = "info@mintel.me";
+    console.warn("MAIL_FROM is empty. Using fallback: info@mintel.me");
+  }
+
+  if (!recipients) {
+    recipients = "marc@mintel.me";
+    console.warn("MAIL_RECIPIENTS is empty. Using fallback: marc@mintel.me");
+  }
+
   const transporter = getTransporter();
 
   const mailOptions = {
-    from: env.MAIL_FROM,
+    from,
     to: recipients,
     replyTo,
     subject,