fix: Windows worktree creation falls back gracefully instead of using temp dirs

PolyPilot.Tests/RepoManagerTests.cs

@@ -6,6 +6,16 @@ namespace PolyPilot.Tests;
 [Collection("BaseDir")]
 public class RepoManagerTests
 {
+    /// <summary>
+    /// Create the minimal files a bare git repo needs so IsValidBareRepository returns true.
+    /// </summary>
+    private static void CreateFakeBareRepoSkeleton(string bareDir)
+    {
+        Directory.CreateDirectory(bareDir);
+        Directory.CreateDirectory(Path.Combine(bareDir, "refs"));
+        File.WriteAllText(Path.Combine(bareDir, "HEAD"), "ref: refs/heads/main\n");
+    }
+
     [Theory]
     [InlineData("https://github.com/Owner/Repo.git", "Owner-Repo")]
     [InlineData("https://github.com/Owner/Repo", "Owner-Repo")]
@@ -365,7 +375,7 @@ public void HealMissingRepos_DiscoversUntracked_BareClones()
         {
             // Create a fake bare clone directory with a git config
             var bareDir = Path.Combine(reposDir, "Owner-Repo.git");
-            Directory.CreateDirectory(bareDir);
+            CreateFakeBareRepoSkeleton(bareDir);
             File.WriteAllText(Path.Combine(bareDir, "config"),
                 "[remote \"origin\"]\n\turl = https://github.com/Owner/Repo\n\tfetch = +refs/heads/*:refs/remotes/origin/*\n");
 
@@ -458,7 +468,7 @@ public void HealMissingRepos_MultipleUntracked_AllDiscovered()
             foreach (var name in new[] { "dotnet-maui.git", "PureWeen-PolyPilot.git", "github-sdk.git" })
             {
                 var dir = Path.Combine(reposDir, name);
-                Directory.CreateDirectory(dir);
+                CreateFakeBareRepoSkeleton(dir);
                 File.WriteAllText(Path.Combine(dir, "config"),
                     $"[remote \"origin\"]\n\turl = https://github.com/test/{name.Replace(".git", "")}\n");
             }
@@ -501,7 +511,7 @@ public void Load_WithCorruptedState_HealsFromDisk()
         {
             // Create a bare clone on disk
             var bareDir = Path.Combine(reposDir, "Owner-Repo.git");
-            Directory.CreateDirectory(bareDir);
+            CreateFakeBareRepoSkeleton(bareDir);
             File.WriteAllText(Path.Combine(bareDir, "config"),
                 "[remote \"origin\"]\n\turl = https://github.com/Owner/Repo\n");
 

PolyPilot.Tests/WorktreeStrategyTests.cs

@@ -769,4 +769,189 @@ public async Task FullyIsolated_WorktreeIdSetOnAgentSessionInfo()
     }
 
     #endregion
+
+    #region Worktree Failure Fallback (Windows long-path / git failure scenarios)
+
+    [Fact]
+    public async Task GroupShared_WorktreeFailure_FallsBackToExistingWorktree()
+    {
+        // Simulate scenario: worktree creation fails (e.g., Windows long-path issue)
+        // but an existing worktree for the repo exists — should use it instead of temp dir.
+        var wtDir = Path.Combine(Path.GetTempPath(), $"wt-fallback-test-{Guid.NewGuid():N}");
+        Directory.CreateDirectory(wtDir);
+        try
+        {
+            var existingWt = new WorktreeInfo
+            {
+                Id = "existing-wt",
+                RepoId = "repo-1",
+                Branch = "main",
+                Path = wtDir
+            };
+            var rm = new FailingRepoManagerWithExistingWorktree(
+                new() { new() { Id = "repo-1", Name = "Repo" } },
+                new() { existingWt });
+            var svc = CreateDemoService(rm);
+            var preset = MakePreset(2, WorktreeStrategy.GroupShared);
+
+            var group = await svc.CreateGroupFromPresetAsync(preset,
+                workingDirectory: null,
+                repoId: "repo-1");
+
+            Assert.NotNull(group);
+            // Borrowed worktree should NOT set group.WorktreeId (prevents DeleteGroup from destroying it)
+            Assert.Null(group!.WorktreeId);
+
+            // Session metadata WorktreeId must also be null — DeleteGroup collects from
+            // session metadata too, so borrowed IDs must not leak there.
+            var allMetas = svc.Organization.Sessions
+                .Where(s => s.GroupId == group!.Id)
+                .ToList();
+            Assert.All(allMetas, m => Assert.Null(m.WorktreeId));
+
+            // Sessions should use the existing worktree path, not a temp dir
+            var organized = svc.GetOrganizedSessions();
+            var groupSessions = organized.FirstOrDefault(g => g.Group.Id == group!.Id).Sessions;
+            Assert.NotNull(groupSessions);
+            Assert.All(groupSessions, s =>
+            {
+                Assert.NotNull(s.WorkingDirectory);
+                Assert.Equal(wtDir, s.WorkingDirectory);
+            });
+        }
+        finally
+        {
+            try { Directory.Delete(wtDir, true); } catch { }
+        }
+    }
+
+    [Fact]
+    public async Task GroupShared_WorktreeFailure_WithWorkingDirectory_UsesWorkingDirectory()
+    {
+        // When worktree creation fails but a workingDirectory was provided,
+        // sessions should use the workingDirectory (not temp)
+        var rm = new FailingRepoManager(new() { new() { Id = "repo-1", Name = "Repo" } });
+        var svc = CreateDemoService(rm);
+        var preset = MakePreset(2, WorktreeStrategy.GroupShared);
+
+        var group = await svc.CreateGroupFromPresetAsync(preset,
+            workingDirectory: "/provided/fallback",
+            repoId: "repo-1");
+
+        Assert.NotNull(group);
+
+        // orchWorkDir should still be /provided/fallback since worktree failed
+        var organized = svc.GetOrganizedSessions();
+        var groupSessions = organized.FirstOrDefault(g => g.Group.Id == group!.Id).Sessions;
+        Assert.NotNull(groupSessions);
+        Assert.All(groupSessions, s =>
+        {
+            Assert.NotNull(s.WorkingDirectory);
+            Assert.Equal("/provided/fallback", s.WorkingDirectory);
+        });
+    }
+
+    [Fact]
+    public async Task FullyIsolated_WorktreeFailure_FallsBackToExistingWorktree()
+    {
+        var wtDir = Path.Combine(Path.GetTempPath(), $"wt-fallback-test-{Guid.NewGuid():N}");
+        Directory.CreateDirectory(wtDir);
+        try
+        {
+            var existingWt = new WorktreeInfo
+            {
+                Id = "existing-wt",
+                RepoId = "repo-1",
+                Branch = "main",
+                Path = wtDir
+            };
+            var rm = new FailingRepoManagerWithExistingWorktree(
+                new() { new() { Id = "repo-1", Name = "Repo" } },
+                new() { existingWt });
+            var svc = CreateDemoService(rm);
+            var preset = MakePreset(2, WorktreeStrategy.FullyIsolated);
+
+            var group = await svc.CreateGroupFromPresetAsync(preset,
+                workingDirectory: null,
+                repoId: "repo-1");
+
+            Assert.NotNull(group);
+            // Borrowed worktree should NOT set group.WorktreeId (prevents DeleteGroup from destroying it)
+            Assert.Null(group!.WorktreeId);
+
+            // Session metadata WorktreeId must also be null — DeleteGroup collects from
+            // session metadata too, so borrowed IDs must not leak there.
+            Assert.All(svc.Organization.Sessions.Where(s => s.GroupId == group!.Id),
+                m => Assert.Null(m.WorktreeId));
+
+            // Sessions should still be created
+            var members = svc.Organization.Sessions
+                .Where(s => s.GroupId == group!.Id)
+                .ToList();
+            Assert.Equal(3, members.Count); // 1 orch + 2 workers
+
+            // All sessions should use the existing worktree path, not a temp dir
+            var organized = svc.GetOrganizedSessions();
+            var groupSessions = organized.FirstOrDefault(g => g.Group.Id == group!.Id).Sessions;
+            Assert.NotNull(groupSessions);
+            Assert.All(groupSessions, s =>
+            {
+                Assert.NotNull(s.WorkingDirectory);
+                Assert.Equal(wtDir, s.WorkingDirectory);
+            });
+        }
+        finally
+        {
+            try { Directory.Delete(wtDir, true); } catch { }
+        }
+    }
+
+    [Fact]
+    public async Task GroupShared_BranchName_UsesSharedPrefix()
+    {
+        // GroupShared should create a worktree with "-shared-" in the branch name,
+        // not "-orchestrator-" — this is the explicit handling fix.
+        var rm = new FakeRepoManager(new() { new() { Id = "repo-1", Name = "Repo" } });
+        var svc = CreateDemoService(rm);
+        var preset = MakePreset(2, WorktreeStrategy.GroupShared);
+
+        await svc.CreateGroupFromPresetAsync(preset,
+            workingDirectory: null,
+            repoId: "repo-1",
+            nameOverride: "MyTeam");
+
+        Assert.Single(rm.CreateCalls);
+        Assert.Contains("shared", rm.CreateCalls[0].BranchName);
+        Assert.DoesNotContain("orchestrator", rm.CreateCalls[0].BranchName);
+    }
+
+    /// <summary>
+    /// A FailingRepoManager that also has existing worktrees in its state,
+    /// so the fallback logic can find them.
+    /// </summary>
+    private class FailingRepoManagerWithExistingWorktree : RepoManager
+    {
+        public FailingRepoManagerWithExistingWorktree(List<RepositoryInfo> repos, List<WorktreeInfo> worktrees)
+        {
+            var stateField = typeof(RepoManager).GetField("_state",
+                System.Reflection.BindingFlags.NonPublic | System.Reflection.BindingFlags.Instance)!;
+            var loadedField = typeof(RepoManager).GetField("_loaded",
+                System.Reflection.BindingFlags.NonPublic | System.Reflection.BindingFlags.Instance)!;
+            stateField.SetValue(this, new RepositoryState { Repositories = repos, Worktrees = worktrees });
+            loadedField.SetValue(this, true);
+        }
+
+        public override Task<WorktreeInfo> CreateWorktreeAsync(string repoId, string branchName,
+            string? baseBranch = null, bool skipFetch = false, CancellationToken ct = default)
+        {
+            throw new InvalidOperationException("Simulated Windows long-path failure");
+        }
+
+        public override Task FetchAsync(string repoId, CancellationToken ct = default)
+        {
+            return Task.CompletedTask; // Fetch succeeds, only worktree creation fails
+        }
+    }
+
+    #endregion
 }

PolyPilot/Services/CopilotService.Organization.cs

@@ -3622,14 +3622,15 @@ public string GetEffectiveModel(string sessionName)
         var orchWorkDir = workingDirectory;
         var orchWtId = worktreeId;
 
-        // Pre-fetch once to avoid parallel git lock contention (local mode only; server handles fetch in remote)
-        if (repoId != null && strategy != WorktreeStrategy.Shared && !IsRemoteMode)
+        // Pre-fetch once to avoid parallel git lock contention (local mode only; server handles fetch in remote).
+        // Shared and GroupShared fetch inside their own block below.
+        if (repoId != null && strategy != WorktreeStrategy.Shared && strategy != WorktreeStrategy.GroupShared && !IsRemoteMode)
         {
             try { await _repoManager.FetchAsync(repoId, ct); }
             catch (Exception ex) { Debug($"Pre-fetch failed (continuing): {ex.Message}"); }
         }
 
-        // For Shared strategy with a repo but no worktree, create a single shared worktree
+        // For Shared strategy with a repo but no worktree/dir, create a single shared worktree
         if (repoId != null && strategy == WorktreeStrategy.Shared && string.IsNullOrEmpty(worktreeId) && string.IsNullOrEmpty(workingDirectory))
         {
             try
@@ -3643,11 +3644,45 @@ public string GetEffectiveModel(string sessionName)
             }
             catch (Exception ex)
             {
-                Debug($"Failed to create shared worktree (sessions will use temp dirs): {ex.Message}");
+                Debug($"[WorktreeStrategy] Failed to create shared worktree for strategy={strategy}, repoId={repoId}: {ex.GetType().Name}: {ex.Message}");
+                orchWorkDir = TryGetExistingWorktreePath(repoId);
+                if (orchWorkDir != null)
+                    Debug($"[WorktreeStrategy] Using existing worktree as fallback: {orchWorkDir}");
+                else
+                    Debug($"[WorktreeStrategy] No existing worktree found — sessions will use temp dirs");
             }
         }
 
-        if (repoId != null && strategy != WorktreeStrategy.Shared && string.IsNullOrEmpty(worktreeId))
+        // GroupShared: always create one shared worktree for the group (even if workingDirectory is set,
+        // because the group needs its own branch). Uses same naming as Shared.
+        if (repoId != null && strategy == WorktreeStrategy.GroupShared && string.IsNullOrEmpty(worktreeId))
+        {
+            try
+            {
+                if (!IsRemoteMode) await _repoManager.FetchAsync(repoId, ct);
+                var sharedWt = await CreateWorktreeLocalOrRemoteAsync(repoId, $"{branchPrefix}-shared-{Guid.NewGuid().ToString()[..4]}", ct);
+                orchWorkDir = sharedWt.Path;
+                orchWtId = sharedWt.Id;
+                group.WorktreeId = orchWtId;
+                group.CreatedWorktreeIds.Add(orchWtId);
+            }
+            catch (Exception ex)
+            {
+                Debug($"[WorktreeStrategy] Failed to create shared worktree for strategy={strategy}, repoId={repoId}: {ex.GetType().Name}: {ex.Message}");
+                // Try to fall back to an existing worktree for this repo instead of temp dir
+                if (orchWorkDir == null)
+                {
+                    orchWorkDir = TryGetExistingWorktreePath(repoId);
+                    if (orchWorkDir != null)
+                        Debug($"[WorktreeStrategy] Using existing worktree as fallback: {orchWorkDir}");
+                    else
+                        Debug($"[WorktreeStrategy] No existing worktree found — sessions will use temp dirs");
+                }
+            }
+        }
+
+        // OrchestratorIsolated / FullyIsolated: create a dedicated orchestrator worktree
+        if (repoId != null && strategy != WorktreeStrategy.Shared && strategy != WorktreeStrategy.GroupShared && string.IsNullOrEmpty(worktreeId))
         {
             try
             {
@@ -3659,7 +3694,15 @@ public string GetEffectiveModel(string sessionName)
             }
             catch (Exception ex)
             {
-                Debug($"Failed to create orchestrator worktree (falling back to shared): {ex.Message}");
+                Debug($"[WorktreeStrategy] Failed to create orchestrator worktree for strategy={strategy}, repoId={repoId}: {ex.GetType().Name}: {ex.Message}");
+                if (orchWorkDir == null)
+                {
+                    orchWorkDir = TryGetExistingWorktreePath(repoId);
+                    if (orchWorkDir != null)
+                        Debug($"[WorktreeStrategy] Using existing worktree as fallback: {orchWorkDir}");
+                    else
+                        Debug($"[WorktreeStrategy] No existing worktree found — sessions will use temp dirs");
+                }
             }
         }
 
@@ -3679,7 +3722,8 @@ public string GetEffectiveModel(string sessionName)
                 }
                 catch (Exception ex)
                 {
-                    Debug($"Failed to create worker-{i + 1} worktree (falling back to shared): {ex.Message}");
+                    Debug($"[WorktreeStrategy] Failed to create worker-{i + 1} worktree: {ex.GetType().Name}: {ex.Message}");
+                    Debug($"[WorktreeStrategy] Worker-{i + 1} will fall back to orchestrator dir: {orchWorkDir}");
                 }
             }
         }
@@ -3697,7 +3741,7 @@ public string GetEffectiveModel(string sessionName)
             }
             catch (Exception ex)
             {
-                Debug($"Failed to create shared worker worktree (falling back to shared): {ex.Message}");
+                Debug($"[WorktreeStrategy] Failed to create shared worker worktree: {ex.GetType().Name}: {ex.Message}");
             }
         }
 
@@ -4681,5 +4725,18 @@ private void AutoAdjustFromFeedback(string groupId, SessionGroup group, List<Wor
         }
     }
 
+    /// <summary>
+    /// When worktree creation fails (e.g., long paths on Windows), try to find an existing
+    /// worktree for the repo so sessions get a real working directory instead of a temp dir.
+    /// Returns only the path — does NOT propagate the worktree ID. This prevents the borrowed
+    /// ID from leaking into session metadata, which would cause DeleteGroup to destroy a
+    /// worktree that belongs to another group (DeleteGroup collects IDs from session metadata).
+    /// </summary>
+    private string? TryGetExistingWorktreePath(string repoId)
+    {
+        var existing = _repoManager.Worktrees.FirstOrDefault(w => w.RepoId == repoId && Directory.Exists(w.Path));
+        return existing?.Path;
+    }
+
     #endregion
 }