fix: install linux sysroot in configure, not via gclient hook (#653)

* fix: install linux sysroot in configure, not via gclient hook

`gn gen` was failing on the arm64 leg with `Missing sysroot
(//build/linux/debian_bullseye_arm64-sysroot)`. The previous design
relied on `git_setup` writing `target_cpus` to `.gclient` so that
`gclient sync`'s DEPS hook would download the cross-arch sysroot. That
chain breaks for any chromium_src that was synced before cross-arch
support landed (the hook is gated on .gclient state at sync time) and
for partial pipeline runs that skip git_setup entirely. Nothing in
configure declared or verified its sysroot precondition.

Make configure self-healing: on Linux, invoke
`build/linux/sysroot_scripts/install-sysroot.py --arch=<target>`
directly before `gn gen`. install-sysroot.py is idempotent (stamp file
+ SHA check), fast when already installed, and decoupled from .gclient
— it's exactly what the failing assertion's error message recommends.
The script accepts our arch names directly: `x64` translates to `amd64`
internally via ARCH_TRANSLATIONS, and `arm64` is a valid pass-through.

Also temporarily pin release.linux.yaml to x64 only while we validate
the sysroot bootstrap end-to-end. Flip back to `[x64, arm64]` once
arm64 is green.

* chore: pin release.linux.yaml to arm64-only for sysroot bootstrap test

x64 already builds cleanly — the failing leg is arm64 cross-compile from
an x64 host. Pin the config to arm64 to exercise the new
install-sysroot.py path in configure without burning time on x64.
Flip back to [x64, arm64] once arm64 is green.

packages/browseros/build/config/release.linux.yaml

@@ -1,8 +1,8 @@
 # BrowserOS Linux Release Build Configuration
 #
-# Builds both x64 and arm64 in a single invocation on a Linux x64 host.
-# The runner loops the entire pipeline once per architecture; depot_tools
-# fetches the matching sysroots automatically (see git_setup module).
+# Pinned to arm64-only to validate the cross-compile sysroot bootstrap
+# end-to-end on a Linux x64 host. Flip back to `[x64, arm64]` once arm64
+# is green.
 #
 # Run:
 #   browseros build --config build/config/release.linux.yaml
@@ -13,7 +13,7 @@
 
 build:
   type: release
-  architecture: [x64, arm64]  # Builds both arches sequentially in one run
+  architecture: arm64
 
 gn_flags:
   file: build/config/gn/flags.linux.release.gn

packages/browseros/build/modules/setup/configure.py

@@ -1,9 +1,19 @@
 #!/usr/bin/env python3
 """Build configuration module for BrowserOS build system"""
 
+import sys
+
 from ...common.module import CommandModule, ValidationError
 from ...common.context import Context
-from ...common.utils import run_command, log_info, log_success, join_paths, IS_WINDOWS
+from ...common.utils import (
+    run_command,
+    log_info,
+    log_warning,
+    log_success,
+    join_paths,
+    IS_LINUX,
+    IS_WINDOWS,
+)
 
 
 class ConfigureModule(CommandModule):
@@ -25,6 +35,16 @@ class ConfigureModule(CommandModule):
     def execute(self, ctx: Context) -> None:
         log_info(f"\n⚙️  Configuring {ctx.build_type} build for {ctx.architecture}...")
 
+        # Linux: ensure the target-arch Debian sysroot is installed before
+        # `gn gen`. sysroot.gni asserts on missing sysroots, and relying on
+        # `gclient sync` DEPS hooks is fragile — the hook only fires when
+        # .gclient declared the right `target_cpus` *before* sync, which
+        # isn't guaranteed for chromium_src checkouts that predate
+        # cross-arch support. install-sysroot.py is idempotent and fast,
+        # so call it unconditionally for the target arch.
+        if IS_LINUX():
+            self._ensure_linux_sysroot(ctx)
+
         out_path = join_paths(ctx.chromium_src, ctx.out_dir)
         out_path.mkdir(parents=True, exist_ok=True)
 
@@ -43,3 +63,26 @@ class ConfigureModule(CommandModule):
         run_command(gn_args, cwd=ctx.chromium_src)
 
         log_success("Build configured")
+
+    def _ensure_linux_sysroot(self, ctx: Context) -> None:
+        install_script = (
+            ctx.chromium_src / "build" / "linux" / "sysroot_scripts" / "install-sysroot.py"
+        )
+        if not install_script.exists():
+            log_warning(
+                f"⚠️  install-sysroot.py not found at {install_script}; "
+                f"skipping sysroot bootstrap. gn gen will fail if the "
+                f"{ctx.architecture} sysroot is missing."
+            )
+            return
+
+        # install-sysroot.py accepts our arch names directly: it translates
+        # `x64`→`amd64` internally via ARCH_TRANSLATIONS, and `arm64` is a
+        # valid pass-through value.
+        log_info(
+            f"📦 Ensuring Linux sysroot for {ctx.architecture} (idempotent)..."
+        )
+        run_command(
+            [sys.executable, str(install_script), f"--arch={ctx.architecture}"],
+            cwd=ctx.chromium_src,
+        )