From 21093528a739839351cb27f307a21b3595ff222d Mon Sep 17 00:00:00 2001
From: Anand Chowdhary <mail@anandchowdhary.com>
Date: Sun, 8 Feb 2026 17:59:07 +0100
Subject: [PATCH 1/2] Handle "already in use" error when R2 bucket is already
 mounted

The isR2Mounted() check (which runs `mount | grep` inside the sandbox)
is unreliable and can return false even when the bucket is already
mounted. This causes mountBucket() to be called again on subsequent
requests, throwing InvalidMountConfigError. Rather than relying solely
on the unreliable mount check in the catch block, detect the "already
in use" error message and treat it as a successful mount.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
---
 src/gateway/r2.test.ts | 19 +++++++++++++++++++
 src/gateway/r2.ts      |  6 ++++++
 2 files changed, 25 insertions(+)

diff --git a/src/gateway/r2.test.ts b/src/gateway/r2.test.ts
index 83b03ae43..e6d3a55b4 100644
--- a/src/gateway/r2.test.ts
+++ b/src/gateway/r2.test.ts
@@ -142,6 +142,25 @@ describe('mountR2Storage', () => {
       expect(console.error).toHaveBeenCalledWith('Failed to mount R2 bucket:', expect.any(Error));
     });
 
+    it('returns true when mount fails with "already in use" error', async () => {
+      const { sandbox, mountBucketMock, startProcessMock } = createMockSandbox({ mounted: false });
+      mountBucketMock.mockRejectedValue(
+        new Error('InvalidMountConfigError: Mount path "/data/moltbot" is already in use by bucket "moltbot-data". Unmount the existing bucket first or use a different mount path.'),
+      );
+      startProcessMock.mockResolvedValueOnce(createMockProcess(''));
+
+      const env = createMockEnvWithR2();
+
+      const result = await mountR2Storage(sandbox, env);
+
+      expect(result).toBe(true);
+      expect(console.log).toHaveBeenCalledWith(
+        'R2 bucket already mounted at',
+        '/data/moltbot',
+        '(detected via mount error)',
+      );
+    });
+
     it('returns true if mount fails but check shows it is actually mounted', async () => {
       const { sandbox, mountBucketMock, startProcessMock } = createMockSandbox();
       startProcessMock
diff --git a/src/gateway/r2.ts b/src/gateway/r2.ts
index c95efc40b..124dabe11 100644
--- a/src/gateway/r2.ts
+++ b/src/gateway/r2.ts
@@ -65,6 +65,12 @@ export async function mountR2Storage(sandbox: Sandbox, env: MoltbotEnv): Promise
     const errorMessage = err instanceof Error ? err.message : String(err);
     console.log('R2 mount error:', errorMessage);
 
+    // "already in use" means the bucket is mounted — treat as success
+    if (errorMessage.includes('already in use')) {
+      console.log('R2 bucket already mounted at', R2_MOUNT_PATH, '(detected via mount error)');
+      return true;
+    }
+
     // Check again if it's mounted - the error might be misleading
     if (await isR2Mounted(sandbox)) {
       console.log('R2 bucket is mounted despite error');

From 51aeceebbf829b12f5a22d40a436fb30687ac87d Mon Sep 17 00:00:00 2001
From: Anand Chowdhary <mail@anandchowdhary.com>
Date: Sun, 8 Feb 2026 18:40:23 +0100
Subject: [PATCH 2/2] Ensure gateway is running before syncing to R2

syncToR2 only mounted R2 but never started the gateway. On a fresh
container, openclaw onboard (which creates openclaw.json) only runs
during gateway startup. If "Sync now" is triggered before any other
route starts the gateway, the config file doesn't exist and sync fails
with "no config file found". Call ensureMoltbotGateway before syncing.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
---
 src/gateway/sync.test.ts |  6 +++++-
 src/gateway/sync.ts      | 13 +++++++++++++
 2 files changed, 18 insertions(+), 1 deletion(-)

diff --git a/src/gateway/sync.test.ts b/src/gateway/sync.test.ts
index f062ffed7..b8a89aaef 100644
--- a/src/gateway/sync.test.ts
+++ b/src/gateway/sync.test.ts
@@ -1,4 +1,4 @@
-import { describe, it, expect, beforeEach } from 'vitest';
+import { describe, it, expect, beforeEach, vi } from 'vitest';
 import { syncToR2 } from './sync';
 import {
   createMockEnv,
@@ -8,6 +8,10 @@ import {
   suppressConsole,
 } from '../test-utils';
 
+vi.mock('./process', () => ({
+  ensureMoltbotGateway: vi.fn().mockResolvedValue({ id: 'mock-process' }),
+}));
+
 describe('syncToR2', () => {
   beforeEach(() => {
     suppressConsole();
diff --git a/src/gateway/sync.ts b/src/gateway/sync.ts
index 63808c471..cfc4c48de 100644
--- a/src/gateway/sync.ts
+++ b/src/gateway/sync.ts
@@ -1,6 +1,7 @@
 import type { Sandbox } from '@cloudflare/sandbox';
 import type { MoltbotEnv } from '../types';
 import { R2_MOUNT_PATH } from '../config';
+import { ensureMoltbotGateway } from './process';
 import { mountR2Storage } from './r2';
 import { waitForProcess } from './utils';
 
@@ -35,6 +36,18 @@ export async function syncToR2(sandbox: Sandbox, env: MoltbotEnv): Promise<SyncR
     return { success: false, error: 'R2 storage is not configured' };
   }
 
+  // Ensure the gateway is running — the startup script creates the config
+  // file via `openclaw onboard`, which is required before we can sync
+  try {
+    await ensureMoltbotGateway(sandbox, env);
+  } catch (err) {
+    return {
+      success: false,
+      error: 'Failed to start gateway',
+      details: err instanceof Error ? err.message : 'Unknown error',
+    };
+  }
+
   // Mount R2 if not already mounted
   const mounted = await mountR2Storage(sandbox, env);
   if (!mounted) {