fix: setErrorHandler must be registered before route modules

Fastify resolves each encapsulated child context's error handler at
the time that context is registered. app.ts called
app.setErrorHandler()/setNotFoundHandler() AFTER bootstrapRoutes()
had already registered every domain module's routes (each
app.register(someRoutes) call creates its own child context, since
none of the route modules use fastify-plugin). A handler set on the
parent afterwards does not retroactively apply to already-registered
children, so every module's routes were silently falling back to
Fastify's default {statusCode, error, message} error shape instead
of this app's {success:false, error:{code,message,details},
requestId} envelope, for any thrown error -- not specific to any one
feature. Discovered while building and manually verifying the
002-saas-integration feature's inbound endpoint.

Also fixed the generic error-handler branch to preserve a framework
error's own client-facing statusCode (e.g. 400 for malformed JSON)
instead of always reporting 500.

Added a regression test in tests/unit/app.test.ts that fails without
this fix and passes with it (verified both ways).

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>

src/app.ts

@@ -15,10 +15,10 @@ export async function buildApp(): Promise<FastifyInstance> {
   // Register Bootstrapped Plugins
   await bootstrapPlugins(app);
 
-  // Register Bootstrapped Global Routes
-  await bootstrapRoutes(app);
-
-  // Global Error Handler
+  // Global Error Handler — MUST be registered before any route module is (bootstrapRoutes
+  // below), because Fastify resolves each encapsulated child context's error handler at the
+  // time that context is registered. A handler set after a child module has already been
+  // registered will not retroactively apply to that module's routes/hooks.
   app.setErrorHandler(
     (error: Error | AppError | ZodError, request: FastifyRequest, reply: FastifyReply) => {
       const requestId = request.reqContext?.requestId || (request.id as string) || 'unknown';
@@ -52,6 +52,25 @@ export async function buildApp(): Promise<FastifyInstance> {
         });
       }
 
+      // Framework-level errors (e.g. Fastify's own body-parser/payload errors) already carry
+      // their own client-facing statusCode/code — preserve those rather than reporting every
+      // non-AppError/ZodError as a 500, which would misclassify a client mistake as a server
+      // failure.
+      const frameworkStatusCode = (error as { statusCode?: number }).statusCode;
+      const frameworkCode = (error as { code?: string }).code;
+      if (frameworkStatusCode && frameworkStatusCode >= 400 && frameworkStatusCode < 500) {
+        logger.warn({ requestId, statusCode: frameworkStatusCode }, error.message);
+        return reply.status(frameworkStatusCode).send({
+          success: false,
+          error: {
+            code: frameworkCode ?? 'BAD_REQUEST',
+            message: error.message,
+            details: null,
+          },
+          requestId,
+        });
+      }
+
       logger.error({ error, requestId }, 'Unhandled Server Error');
 
       const responseMessage =
@@ -85,5 +104,9 @@ export async function buildApp(): Promise<FastifyInstance> {
     });
   });
 
+  // Register Bootstrapped Global Routes — MUST come after the handlers above (see comment
+  // on setErrorHandler).
+  await bootstrapRoutes(app);
+
   return app;
 }

tests/unit/app.test.ts

@@ -7,4 +7,32 @@ describe('App Factory Unit Test', () => {
     expect(app).toBeDefined();
     await app.close();
   });
+
+  it('applies the custom error envelope to errors raised inside a registered route module, not just root-level routes', async () => {
+    // Regression test: app.setErrorHandler() must be called BEFORE any route module is
+    // registered (bootstrapRoutes), because Fastify resolves each encapsulated child
+    // context's error handler at registration time — a handler set afterwards does not
+    // retroactively apply to already-registered child modules. This was discovered while
+    // building specs/002-saas-integration: every domain module's routes (registered via
+    // `app.register(someModuleRoutes)`, which creates a child encapsulation context) were
+    // silently falling back to Fastify's default `{statusCode, error, message}` shape
+    // instead of this app's `{success:false, error:{code,message,details}, requestId}`
+    // envelope. Uses malformed JSON against a real registered route (not a synthetic
+    // top-level route) so the error is raised by Fastify's own body parser inside that
+    // module's encapsulation context, with no database/Redis dependency — a regression
+    // here (e.g. someone moving setErrorHandler back after bootstrapRoutes) fails this test.
+    const app = await buildApp();
+    const response = await app.inject({
+      method: 'POST',
+      url: '/v1/support/requests',
+      headers: { 'content-type': 'application/json' },
+      payload: 'not-valid-json{{{',
+    });
+
+    expect(response.statusCode).toBe(400);
+    const body = response.json();
+    expect(body).toMatchObject({ success: false, error: { code: expect.any(String) } });
+    expect(body.requestId).toBeDefined();
+    await app.close();
+  });
 });