fix(ripgrep): use @vscode/ripgrep package as the builtin source (#911)

The vendored-binary lookup at vendor/ripgrep/<arch>-<platform>/rg never
resolved in this fork — that directory does not ship — so users without
a system rg had no working fallback. Switch to the @vscode/ripgrep
package so Microsoft maintains the platform/arch matrix and the binary
is delivered via npm.

- src/utils/ripgrep.ts: replace hand-rolled vendor-path resolution with
  rgPath from @vscode/ripgrep. Lazy require so a missing package falls
  through to the system rg branch instead of throwing at import.
  Drop builtinExists from the config args; builtinCommand is now a
  string-or-null. The system override (USE_BUILTIN_RIPGREP=0), the
  Bun-compiled standalone embedded mode, the macOS codesign hook, and
  all retry/timeout/error logic are preserved untouched.
- scripts/build.ts: mark @vscode/ripgrep as external. The package
  resolves rgPath via __dirname at runtime, so bundling would freeze
  the build host's absolute path into dist/cli.mjs.
- src/utils/ripgrep.test.ts: update for the new config shape and add
  tests covering USE_BUILTIN_RIPGREP=0, embedded mode, last-resort
  fallback, and null builtin path.

Tested locally on Linux (Bun 1.3.13). macOS (codesign hook) and
Windows (rg.exe extension) need contributor verification.

.env.example

@@ -421,16 +421,3 @@ ANTHROPIC_API_KEY=sk-ant-your-key-here
 # WEB_CUSTOM_ALLOW_HTTP=false                — set "true" to allow http:// URLs
 # WEB_CUSTOM_ALLOW_PRIVATE=false             — set "true" to target localhost/private IPs
 #                                               (needed for self-hosted SearXNG)
-
-# ── Config directory override ───────────────────────────────────────
-#
-# By default openclaude stores per-user state under ~/.openclaude
-# (and falls back to ~/.claude for installs that pre-date the rename).
-# Set this to point openclaude at a different directory — useful for
-# isolating profiles or sharing config across machines.
-#
-# OPENCLAUDE_CONFIG_DIR=/path/to/dir         — preferred name
-# CLAUDE_CONFIG_DIR=/path/to/dir             — legacy alias (still works)
-#
-# When both are set with different values, OPENCLAUDE_CONFIG_DIR wins
-# and a warning is logged once per process.

bun.lock

@@ -28,6 +28,7 @@
         "@opentelemetry/sdk-trace-base": "2.6.1",
         "@opentelemetry/sdk-trace-node": "2.6.1",
         "@opentelemetry/semantic-conventions": "1.40.0",
+        "@vscode/ripgrep": "^1.17.1",
         "ajv": "8.18.0",
         "auto-bind": "5.0.1",
         "axios": "1.15.0",
@@ -461,6 +462,8 @@
 
     "@types/react": ["@types/react@19.2.14", "", { "dependencies": { "csstype": "^3.2.2" } }, "sha512-ilcTH/UniCkMdtexkoCN0bI7pMcJDvmQFPvuPvmEaYA/NSfFTAgdUSLAoVjaRJm7+6PvcM+q1zYOwS4wTYMF9w=="],
 
+    "@vscode/ripgrep": ["@vscode/ripgrep@1.17.1", "", { "dependencies": { "https-proxy-agent": "^7.0.2", "proxy-from-env": "^1.1.0", "yauzl": "^2.9.2" } }, "sha512-xTs7DGyAO3IsJYOCTBP8LnTvPiYVKEuyv8s0xyJDBXfs8rhBfqnZPvb6xDT+RnwWzcXqW27xLS/aGrkjX7lNWw=="],
+
     "accepts": ["accepts@2.0.0", "", { "dependencies": { "mime-types": "^3.0.0", "negotiator": "^1.0.0" } }, "sha512-5cvg6CtKwfgdmVqY1WIiXKc3Q1bkRqGLi+2W/6ao+6Y7gu/RCwRuAhGEzh5B4KlszSuTLgZYuqFqo5bImjNKng=="],
 
     "agent-base": ["agent-base@7.1.4", "", {}, "sha512-MnA+YT8fwfJPgBx3m60MNqakm30XOkyIoH1y6huTQvC0PwZG7ki8NacLBcrPbNoo8vEZy7Jpuk7+jMO+CUovTQ=="],
@@ -491,6 +494,8 @@
 
     "bowser": ["bowser@2.14.1", "", {}, "sha512-tzPjzCxygAKWFOJP011oxFHs57HzIhOEracIgAePE4pqB3LikALKnSzUyU4MGs9/iCEUuHlAJTjTc5M+u7YEGg=="],
 
+    "buffer-crc32": ["buffer-crc32@0.2.13", "", {}, "sha512-VO9Ht/+p3SN7SKWqcrgEzjGbRSJYTx+Q1pTQC0wrWqHx0vpJraQ6GtHx8tvcg1rlK1byhU5gccxgOgj7B0TDkQ=="],
+
     "buffer-equal-constant-time": ["buffer-equal-constant-time@1.0.1", "", {}, "sha512-zRpUiDwd/xk6ADqPMATG8vc9VPrkck7T07OIx0gnjmJAnHnTVXNQG3vfvWNuiZIkwu9KrKdA1iJKfsfTVxE6NA=="],
 
     "bun-types": ["bun-types@1.3.11", "", { "dependencies": { "@types/node": "*" } }, "sha512-1KGPpoxQWl9f6wcZh57LvrPIInQMn2TQ7jsgxqpRzg+l0QPOFvJVH7HmvHo/AiPgwXy+/Thf6Ov3EdVn1vOabg=="],
@@ -609,6 +614,8 @@
 
     "fast-xml-parser": ["fast-xml-parser@5.5.8", "", { "dependencies": { "fast-xml-builder": "^1.1.4", "path-expression-matcher": "^1.2.0", "strnum": "^2.2.0" }, "bin": { "fxparser": "src/cli/cli.js" } }, "sha512-Z7Fh2nVQSb2d+poDViM063ix2ZGt9jmY1nWhPfHBOK2Hgnb/OW3P4Et3P/81SEej0J7QbWtJqxO05h8QYfK7LQ=="],
 
+    "fd-slicer": ["fd-slicer@1.1.0", "", { "dependencies": { "pend": "~1.2.0" } }, "sha512-cE1qsB/VwyQozZ+q1dGxR8LBYNZeofhEdUNGSMbQD3Gw2lAzX9Zb3uIU6Ebc/Fmyjo9AWWfnn0AUCHqtevs/8g=="],
+
     "fflate": ["fflate@0.8.2", "", {}, "sha512-cPJU47OaAoCbg0pBvzsgpTPhmhqI5eJjh/JIu8tPj5q+T7iLvW/JAYUqmE7KOB4R1ZyEhzBaIQpQpardBF5z8A=="],
 
     "figures": ["figures@6.1.0", "", { "dependencies": { "is-unicode-supported": "^2.0.0" } }, "sha512-d+l3qxjSesT4V7v2fh+QnmFnUWv9lSpjarhShNTgBOfA0ttejbQUAlHLitbjkoRiDulW0OPoQPYIGhIC8ohejg=="],
@@ -787,6 +794,8 @@
 
     "path-to-regexp": ["path-to-regexp@8.4.1", "", {}, "sha512-fvU78fIjZ+SBM9YwCknCvKOUKkLVqtWDVctl0s7xIqfmfb38t2TT4ZU2gHm+Z8xGwgW+QWEU3oQSAzIbo89Ggw=="],
 
+    "pend": ["pend@1.2.0", "", {}, "sha512-F3asv42UuXchdzt+xXqfW1OGlVBe+mxa2mqI0pg5yAHZPvFmY3Y6drSf/GQ1A86WgWEN9Kzh/WrgKa6iGcHXLg=="],
+
     "picomatch": ["picomatch@4.0.4", "", {}, "sha512-QP88BAKvMam/3NxH6vj2o21R6MjxZUAd6nlwAS/pnGvN9IVLocLHxGYIzFhg6fUQ+5th6P4dv4eW9jX3DSIj7A=="],
 
     "pkce-challenge": ["pkce-challenge@5.0.1", "", {}, "sha512-wQ0b/W4Fr01qtpHlqSqspcj3EhBvimsdh0KlHhH8HRZnMsEa0ea2fTULOXOS9ccQr3om+GcGRk4e+isrZWV8qQ=="],
@@ -801,7 +810,7 @@
 
     "proxy-addr": ["proxy-addr@2.0.7", "", { "dependencies": { "forwarded": "0.2.0", "ipaddr.js": "1.9.1" } }, "sha512-llQsMLSUDUPT44jdrU/O37qlnifitDP+ZwrmmZcoSKyLKvtZxpyV0n2/bD/N4tBAAZ/gJEdZU7KMraoK1+XYAg=="],
 
-    "proxy-from-env": ["proxy-from-env@2.1.0", "", {}, "sha512-cJ+oHTW1VAEa8cJslgmUZrc+sjRKgAKl3Zyse6+PV38hZe/V6Z14TbCuXcan9F9ghlz4QrFr2c92TNF82UkYHA=="],
+    "proxy-from-env": ["proxy-from-env@1.1.0", "", {}, "sha512-D+zkORCbA9f1tdWRK0RaCR3GPv50cMxcrz4X8k5LTSUD1Dkw47mKJEZQNunItRTkWwgtaUSo1RVFRIG9ZXiFYg=="],
 
     "qrcode": ["qrcode@1.5.4", "", { "dependencies": { "dijkstrajs": "^1.0.1", "pngjs": "^5.0.0", "yargs": "^15.3.1" }, "bin": { "qrcode": "bin/qrcode" } }, "sha512-1ca71Zgiu6ORjHqFBDpnSMTR2ReToX4l1Au1VFLyVeBTFavzQnv5JxMFr3ukHVKpSrSA2MCk0lNJSykjUfz7Zg=="],
 
@@ -953,6 +962,8 @@
 
     "yargs-parser": ["yargs-parser@21.1.1", "", {}, "sha512-tVpsJW7DdjecAiFpbIB1e3qxIQsE6NoPc5/eTdrbbIC4h0LVsWhnoa3g+m2HclBIujHzsxZ4VJVA+GUuc2/LBw=="],
 
+    "yauzl": ["yauzl@2.10.0", "", { "dependencies": { "buffer-crc32": "~0.2.3", "fd-slicer": "~1.1.0" } }, "sha512-p4a9I6X6nu6IhoGmBqAcbJy1mlC4j27vEPZX9F4L4/vZT3Lyq1VkFHw/V/PUcB9Buo+DG3iHkT0x3Qya58zc3g=="],
+
     "yoctocolors": ["yoctocolors@2.1.2", "", {}, "sha512-CzhO+pFNo8ajLM2d2IW/R93ipy99LWjtwblvC1RsoSUMZgyLbYFr221TnSNT7GjGdYui6P459mw9JH/g/zW2ug=="],
 
     "zod": ["zod@3.25.76", "", {}, "sha512-gzUt/qt81nXsFGKIFcC3YnfEAx5NkunCfnDlvuBSSFS02bcXu4Lmea0AFIUwbLWxWPx3d9p8S5QoaujKcNQxcQ=="],
@@ -1369,6 +1380,8 @@
 
     "@smithy/uuid/tslib": ["tslib@2.8.1", "", {}, "sha512-oJFu94HQb+KVduSUQL7wnpmqnfmLsOA/nAh6b6EH0wCEoK0/mPeXU6c3wKDV83MkOuHPRHtSXKKU99IBazS/2w=="],
 
+    "axios/proxy-from-env": ["proxy-from-env@2.1.0", "", {}, "sha512-cJ+oHTW1VAEa8cJslgmUZrc+sjRKgAKl3Zyse6+PV38hZe/V6Z14TbCuXcan9F9ghlz4QrFr2c92TNF82UkYHA=="],
+
     "cli-highlight/chalk": ["chalk@4.1.2", "", { "dependencies": { "ansi-styles": "^4.1.0", "supports-color": "^7.1.0" } }, "sha512-oKnbhFyRIXpUuez8iBMmyEa4nbj4IOQyuhc/wy9kY7/WVPcwIO9VA668Pu8RkO7+0G76SLROeyw9CpQ061i4mA=="],
 
     "cli-highlight/yargs": ["yargs@16.2.0", "", { "dependencies": { "cliui": "^7.0.2", "escalade": "^3.1.1", "get-caller-file": "^2.0.5", "require-directory": "^2.1.1", "string-width": "^4.2.0", "y18n": "^5.0.5", "yargs-parser": "^20.2.2" } }, "sha512-D1mvvtDG0L5ft/jGWkLpG1+m0eQxOfaBvTNELraWj22wSVUMWxZUvYgJYcKh6jGGIkJFhH4IZPQhR4TKpc8mBw=="],
@@ -1429,6 +1442,8 @@
 
     "@aws-sdk/nested-clients/@smithy/util-base64/@smithy/util-buffer-from": ["@smithy/util-buffer-from@4.2.2", "", { "dependencies": { "@smithy/is-array-buffer": "^4.2.2", "tslib": "^2.6.2" } }, "sha512-FDXD7cvUoFWwN6vtQfEta540Y/YBe5JneK3SoZg9bThSoOAC/eGeYEua6RkBgKjGa/sz6Y+DuBZj3+YEY21y4Q=="],
 
+    "@mendable/firecrawl-js/axios/proxy-from-env": ["proxy-from-env@2.1.0", "", {}, "sha512-cJ+oHTW1VAEa8cJslgmUZrc+sjRKgAKl3Zyse6+PV38hZe/V6Z14TbCuXcan9F9ghlz4QrFr2c92TNF82UkYHA=="],
+
     "@opentelemetry/exporter-trace-otlp-grpc/@opentelemetry/core/@opentelemetry/semantic-conventions": ["@opentelemetry/semantic-conventions@1.28.0", "", {}, "sha512-lp4qAiMTD4sNWW4DbKLBkfiMZ4jbAboJIGOQr5DvciMRI494OapieI9qiODpOt0XBr1LjIDy1xAGAnVs5supTA=="],
 
     "@opentelemetry/exporter-trace-otlp-grpc/@opentelemetry/otlp-transformer/@opentelemetry/api-logs": ["@opentelemetry/api-logs@0.57.2", "", { "dependencies": { "@opentelemetry/api": "^1.3.0" } }, "sha512-uIX52NnTM0iBh84MShlpouI7UKqkZ7MrUszTmaypHBu4r7NofznSnQRfJ+uUeDtQDj6w8eFGg5KBLDAwAPz1+A=="],
@@ -1509,6 +1524,8 @@
 
     "cliui/wrap-ansi/ansi-styles": ["ansi-styles@4.3.0", "", { "dependencies": { "color-convert": "^2.0.1" } }, "sha512-zbB9rCJAT1rbjiVDb2hqKFHNYLxgtk8NURxZ3IZwD3F6NtxbXZQCnnSi1Lkx+IDohdPlFp222wVALIheZJQSEg=="],
 
+    "firecrawl/axios/proxy-from-env": ["proxy-from-env@2.1.0", "", {}, "sha512-cJ+oHTW1VAEa8cJslgmUZrc+sjRKgAKl3Zyse6+PV38hZe/V6Z14TbCuXcan9F9ghlz4QrFr2c92TNF82UkYHA=="],
+
     "form-data/mime-types/mime-db": ["mime-db@1.52.0", "", {}, "sha512-sPU4uV7dYlvtWJxwwxHD0PuihVNiE7TyAbQ5SWxDCB9mUYvOgroQOwYQQOKPJ8CIbE+1ETVlOoK1UC2nU3gYvg=="],
 
     "qrcode/yargs/cliui": ["cliui@6.0.0", "", { "dependencies": { "string-width": "^4.2.0", "strip-ansi": "^6.0.0", "wrap-ansi": "^6.2.0" } }, "sha512-t6wbgtoCXvAzst7QgXxJYqPt0usEfbgQdftEPbLL/cvv6HPE5VgvqCuAIDR0NgU52ds6rFwqrgakNLrHEjCbrQ=="],

package.json

@@ -74,6 +74,7 @@
     "@opentelemetry/sdk-trace-base": "2.6.1",
     "@opentelemetry/sdk-trace-node": "2.6.1",
     "@opentelemetry/semantic-conventions": "1.40.0",
+    "@vscode/ripgrep": "^1.17.1",
     "ajv": "8.18.0",
     "auto-bind": "5.0.1",
     "axios": "1.15.0",

scripts/build.ts

@@ -472,6 +472,11 @@ ${exports}
     '@aws-sdk/credential-providers',
     '@azure/identity',
     'google-auth-library',
+    // @vscode/ripgrep ships a platform-specific binary alongside its
+    // index.js and resolves the path via __dirname at runtime. Bundling
+    // would freeze the build host's absolute path into dist/cli.mjs, so we
+    // keep it external and rely on the npm package being installed.
+    '@vscode/ripgrep',
   ],
 })
 

src/utils/env.ts

@@ -3,11 +3,7 @@ import { homedir } from 'os'
 import { join } from 'path'
 import { fileSuffixForOauthConfig } from '../constants/oauth.js'
 import { isRunningWithBun } from './bundledMode.js'
-import {
+import { getClaudeConfigHomeDir, isEnvTruthy } from './envUtils.js'
-  getClaudeConfigHomeDir,
-  isEnvTruthy,
-  resolveConfigDirEnv,
-} from './envUtils.js'
 import { findExecutable } from './findExecutable.js'
 import { getFsImplementation } from './fsOperations.js'
 import { which } from './which.js'
@@ -26,11 +22,7 @@ export const getGlobalClaudeFile = memoize((): string => {
   }
 
   const oauthSuffix = fileSuffixForOauthConfig()
-  const configDir =
+  const configDir = process.env.CLAUDE_CONFIG_DIR || homedir()
-    resolveConfigDirEnv({
-      openClaudeConfigDir: process.env.OPENCLAUDE_CONFIG_DIR,
-      legacyConfigDir: process.env.CLAUDE_CONFIG_DIR,
-    }) ?? homedir()
 
   // Default to .openclaude.json. Fall back to .claude.json only if the new
   // file doesn't exist yet and the legacy one does (same migration pattern

src/utils/envUtils.ts

@@ -3,39 +3,6 @@ import { existsSync } from 'fs'
 import { homedir } from 'os'
 import { join } from 'path'
 
-/**
- * Resolves the override env value for the config home directory.
- * `OPENCLAUDE_CONFIG_DIR` is preferred — `CLAUDE_CONFIG_DIR` is the legacy
- * Anthropic name kept working for backward compatibility. When both are set
- * and disagree, `OPENCLAUDE_CONFIG_DIR` wins and we warn once so the user
- * can clean up. Exported for tests.
- */
-let warnedAboutConflictingConfigDirEnvs = false
-
-export function resolveConfigDirEnv(options?: {
-  openClaudeConfigDir?: string
-  legacyConfigDir?: string
-  warn?: (message: string) => void
-}): string | undefined {
-  const open = options?.openClaudeConfigDir
-  const legacy = options?.legacyConfigDir
-  if (open && legacy && open !== legacy && !warnedAboutConflictingConfigDirEnvs) {
-    warnedAboutConflictingConfigDirEnvs = true
-    options?.warn?.(
-      `Both OPENCLAUDE_CONFIG_DIR and CLAUDE_CONFIG_DIR are set to different values. Using OPENCLAUDE_CONFIG_DIR=${open}; ignoring CLAUDE_CONFIG_DIR=${legacy}.`,
-    )
-  }
-  return open || legacy || undefined
-}
-
-/**
- * Test-only escape hatch — resets the once-per-process conflict warning so
- * unit tests can re-trigger it.
- */
-export function __resetConfigDirEnvWarningForTesting(): void {
-  warnedAboutConflictingConfigDirEnvs = false
-}
-
 export function resolveClaudeConfigHomeDir(options?: {
   configDirEnv?: string
   homeDir?: string
@@ -63,21 +30,13 @@ export function resolveClaudeConfigHomeDir(options?: {
   return openClaudeDir.normalize('NFC')
 }
 
-// Memoized: 150+ callers, many on hot paths. Keyed off both override env
+// Memoized: 150+ callers, many on hot paths. Keyed off CLAUDE_CONFIG_DIR so
-// vars so tests that change either get a fresh value without explicit
+// tests that change the env var get a fresh value without explicit cache.clear.
-// cache.clear.
 export const getClaudeConfigHomeDir = memoize(
   (): string => resolveClaudeConfigHomeDir({
-    configDirEnv: resolveConfigDirEnv({
+    configDirEnv: process.env.CLAUDE_CONFIG_DIR,
-      openClaudeConfigDir: process.env.OPENCLAUDE_CONFIG_DIR,
-      legacyConfigDir: process.env.CLAUDE_CONFIG_DIR,
-      warn: message => {
-        // eslint-disable-next-line no-console
-        console.warn(`[openclaude] ${message}`)
-      },
-    }),
   }),
-  () => `${process.env.OPENCLAUDE_CONFIG_DIR ?? ''}|${process.env.CLAUDE_CONFIG_DIR ?? ''}`,
+  () => process.env.CLAUDE_CONFIG_DIR,
 )
 
 export function getTeamsDir(): string {

src/utils/openclaudePaths.test.ts

@@ -51,8 +51,7 @@ describe('OpenClaude paths', () => {
     ).toBe(join(homedir(), '.claude'))
   })
 
-  test('uses CLAUDE_CONFIG_DIR override when provided (legacy)', async () => {
+  test('uses CLAUDE_CONFIG_DIR override when provided', async () => {
-    delete process.env.OPENCLAUDE_CONFIG_DIR
     process.env.CLAUDE_CONFIG_DIR = '/tmp/custom-openclaude'
     const { getClaudeConfigHomeDir, resolveClaudeConfigHomeDir } =
       await importFreshEnvUtils()
@@ -65,83 +64,6 @@ describe('OpenClaude paths', () => {
     ).toBe('/tmp/custom-openclaude')
   })
 
-  test('OPENCLAUDE_CONFIG_DIR overrides the default (issue #454)', async () => {
-    delete process.env.CLAUDE_CONFIG_DIR
-    process.env.OPENCLAUDE_CONFIG_DIR = '/tmp/oc-config-only'
-    const { getClaudeConfigHomeDir } = await importFreshEnvUtils()
-
-    expect(getClaudeConfigHomeDir()).toBe('/tmp/oc-config-only')
-  })
-
-  test('OPENCLAUDE_CONFIG_DIR wins when both env vars are set with different values', async () => {
-    process.env.OPENCLAUDE_CONFIG_DIR = '/tmp/oc-wins'
-    process.env.CLAUDE_CONFIG_DIR = '/tmp/legacy-loses'
-    const { getClaudeConfigHomeDir } = await importFreshEnvUtils()
-
-    expect(getClaudeConfigHomeDir()).toBe('/tmp/oc-wins')
-  })
-
-  test('CLAUDE_CONFIG_DIR is still honored when OPENCLAUDE_CONFIG_DIR is unset', async () => {
-    delete process.env.OPENCLAUDE_CONFIG_DIR
-    process.env.CLAUDE_CONFIG_DIR = '/tmp/legacy-only'
-    const { getClaudeConfigHomeDir } = await importFreshEnvUtils()
-
-    expect(getClaudeConfigHomeDir()).toBe('/tmp/legacy-only')
-  })
-
-  test('empty OPENCLAUDE_CONFIG_DIR falls through to CLAUDE_CONFIG_DIR', async () => {
-    process.env.OPENCLAUDE_CONFIG_DIR = ''
-    process.env.CLAUDE_CONFIG_DIR = '/tmp/legacy-fallback'
-    const { getClaudeConfigHomeDir } = await importFreshEnvUtils()
-
-    expect(getClaudeConfigHomeDir()).toBe('/tmp/legacy-fallback')
-  })
-
-  test('resolveConfigDirEnv prefers OPENCLAUDE over CLAUDE and warns on conflict', async () => {
-    const { resolveConfigDirEnv, __resetConfigDirEnvWarningForTesting } =
-      await importFreshEnvUtils()
-    __resetConfigDirEnvWarningForTesting()
-
-    const warnings: string[] = []
-    const result = resolveConfigDirEnv({
-      openClaudeConfigDir: '/a',
-      legacyConfigDir: '/b',
-      warn: m => warnings.push(m),
-    })
-
-    expect(result).toBe('/a')
-    expect(warnings.length).toBe(1)
-    expect(warnings[0]).toContain('OPENCLAUDE_CONFIG_DIR=/a')
-    expect(warnings[0]).toContain('CLAUDE_CONFIG_DIR=/b')
-  })
-
-  test('resolveConfigDirEnv does not warn when both env vars agree', async () => {
-    const { resolveConfigDirEnv, __resetConfigDirEnvWarningForTesting } =
-      await importFreshEnvUtils()
-    __resetConfigDirEnvWarningForTesting()
-
-    const warnings: string[] = []
-    const result = resolveConfigDirEnv({
-      openClaudeConfigDir: '/same',
-      legacyConfigDir: '/same',
-      warn: m => warnings.push(m),
-    })
-
-    expect(result).toBe('/same')
-    expect(warnings).toEqual([])
-  })
-
-  test('resolveConfigDirEnv returns undefined when neither env var is set', async () => {
-    const { resolveConfigDirEnv } = await importFreshEnvUtils()
-
-    expect(
-      resolveConfigDirEnv({
-        openClaudeConfigDir: undefined,
-        legacyConfigDir: undefined,
-      }),
-    ).toBeUndefined()
-  })
-
   test('project and local settings paths use .openclaude', async () => {
     const { getRelativeSettingsFilePathForSource } = await importFreshSettings()
 

src/utils/ripgrep.test.ts

@@ -5,16 +5,15 @@ import { resolveRipgrepConfig, wrapRipgrepUnavailableError } from './ripgrep.js'
 
 const MOCK_BUILTIN_PATH = path.normalize(
   process.platform === 'win32'
-    ? `vendor/ripgrep/${process.arch}-win32/rg.exe`
+    ? `node_modules/@vscode/ripgrep/bin/rg.exe`
-    : `vendor/ripgrep/${process.arch}-${process.platform}/rg`,
+    : `node_modules/@vscode/ripgrep/bin/rg`,
 )
 
-test('ripgrepCommand falls back to system rg when builtin binary is missing', () => {
+test('falls back to system rg when @vscode/ripgrep cannot be resolved', () => {
   const config = resolveRipgrepConfig({
     userWantsSystemRipgrep: false,
     bundledMode: false,
-    builtinCommand: MOCK_BUILTIN_PATH,
+    builtinCommand: null,
-    builtinExists: false,
     systemExecutablePath: '/usr/bin/rg',
     processExecPath: '/fake/bun',
   })
@@ -26,12 +25,11 @@ test('ripgrepCommand falls back to system rg when builtin binary is missing', ()
   })
 })
 
-test('ripgrepCommand keeps builtin mode when bundled binary exists', () => {
+test('uses builtin @vscode/ripgrep path when the package resolves', () => {
   const config = resolveRipgrepConfig({
     userWantsSystemRipgrep: false,
     bundledMode: false,
     builtinCommand: MOCK_BUILTIN_PATH,
-    builtinExists: true,
     systemExecutablePath: '/usr/bin/rg',
     processExecPath: '/fake/bun',
   })
@@ -43,10 +41,59 @@ test('ripgrepCommand keeps builtin mode when bundled binary exists', () => {
   })
 })
 
+test('honors USE_BUILTIN_RIPGREP=0 by selecting system rg even when builtin is available', () => {
+  const config = resolveRipgrepConfig({
+    userWantsSystemRipgrep: true,
+    bundledMode: false,
+    builtinCommand: MOCK_BUILTIN_PATH,
+    systemExecutablePath: '/usr/bin/rg',
+    processExecPath: '/fake/bun',
+  })
+
+  expect(config).toMatchObject({
+    mode: 'system',
+    command: 'rg',
+    args: [],
+  })
+})
+
+test('keeps embedded mode for Bun-compiled standalone executables', () => {
+  const config = resolveRipgrepConfig({
+    userWantsSystemRipgrep: false,
+    bundledMode: true,
+    builtinCommand: null,
+    systemExecutablePath: '/usr/bin/rg',
+    processExecPath: '/opt/openclaude/bin/openclaude',
+  })
+
+  expect(config).toMatchObject({
+    mode: 'embedded',
+    command: '/opt/openclaude/bin/openclaude',
+    args: ['--no-config'],
+    argv0: 'rg',
+  })
+})
+
+test('falls through to system rg as a last resort even when not on PATH', () => {
+  const config = resolveRipgrepConfig({
+    userWantsSystemRipgrep: false,
+    bundledMode: false,
+    builtinCommand: null,
+    systemExecutablePath: 'rg',
+    processExecPath: '/fake/bun',
+  })
+
+  expect(config).toMatchObject({
+    mode: 'system',
+    command: 'rg',
+    args: [],
+  })
+})
+
 test('wrapRipgrepUnavailableError explains missing packaged fallback', () => {
   const error = wrapRipgrepUnavailableError(
     { code: 'ENOENT', message: 'spawn rg ENOENT' },
-    { mode: 'builtin', command: 'C:\\fake\\vendor\\ripgrep\\rg.exe', args: [] },
+    { mode: 'builtin', command: 'C:\\fake\\node_modules\\@vscode\\ripgrep\\bin\\rg.exe', args: [] },
     'win32',
   )
 

src/utils/ripgrep.ts

@@ -5,7 +5,6 @@ import memoize from 'lodash-es/memoize.js'
 import { homedir } from 'os'
 import * as path from 'path'
 import { logEvent } from 'src/services/analytics/index.js'
-import { fileURLToPath } from 'url'
 import { isInBundledMode } from './bundledMode.js'
 import { logForDebugging } from './debug.js'
 import { isEnvDefinedFalsy } from './envUtils.js'
@@ -15,13 +14,6 @@ import { logError } from './log.js'
 import { getPlatform } from './platform.js'
 import { countCharInString } from './stringUtils.js'
 
-const __filename = fileURLToPath(import.meta.url)
-// we use node:path.join instead of node:url.resolve because the former doesn't encode spaces
-const __dirname = path.join(
-  __filename,
-  process.env.NODE_ENV === 'test' ? '../../../' : '../',
-)
-
 type RipgrepConfig = {
   mode: 'system' | 'builtin' | 'embedded'
   command: string
@@ -35,11 +27,31 @@ function isErrnoException(error: unknown): error is NodeJS.ErrnoException {
   return error instanceof Error
 }
 
+/**
+ * Returns the ripgrep binary path provided by the @vscode/ripgrep package.
+ * The package downloads a platform/arch-specific binary at npm install time
+ * (cached under the package's bin/ directory). Returns null when the package
+ * cannot be resolved — for example when running as a Bun-compiled standalone
+ * executable that doesn't ship node_modules.
+ */
+function resolveBuiltinRgPath(): string | null {
+  try {
+    // Lazy require so the resolution failure path stays graceful at import
+    // time. The package only exports `rgPath`, so we do not need the rest.
+    const mod = require('@vscode/ripgrep') as { rgPath?: string }
+    if (mod.rgPath && existsSync(mod.rgPath)) {
+      return mod.rgPath
+    }
+  } catch {
+    // Falls through to null — caller decides the fallback.
+  }
+  return null
+}
+
 type ResolveRipgrepConfigArgs = {
   userWantsSystemRipgrep: boolean
   bundledMode: boolean
-  builtinCommand: string
+  builtinCommand: string | null
-  builtinExists: boolean
   systemExecutablePath: string
   processExecPath?: string
 }
@@ -48,7 +60,6 @@ export function resolveRipgrepConfig({
   userWantsSystemRipgrep,
   bundledMode,
   builtinCommand,
-  builtinExists,
   systemExecutablePath,
   processExecPath = process.execPath,
 }: ResolveRipgrepConfigArgs): RipgrepConfig {
@@ -66,7 +77,7 @@ export function resolveRipgrepConfig({
     }
   }
 
-  if (builtinExists) {
+  if (builtinCommand) {
     return { mode: 'builtin', command: builtinCommand, args: [] }
   }
 
@@ -74,7 +85,9 @@ export function resolveRipgrepConfig({
     return { mode: 'system', command: 'rg', args: [] }
   }
 
-  return { mode: 'builtin', command: builtinCommand, args: [] }
+  // Last resort — leaves error reporting to the executor when no binary
+  // can be located. wrapRipgrepUnavailableError() surfaces an install hint.
+  return { mode: 'system', command: 'rg', args: [] }
 }
 
 const getRipgrepConfig = memoize((): RipgrepConfig => {
@@ -82,19 +95,13 @@ const getRipgrepConfig = memoize((): RipgrepConfig => {
     process.env.USE_BUILTIN_RIPGREP,
   )
   const bundledMode = isInBundledMode()
-  const rgRoot = path.resolve(__dirname, 'vendor', 'ripgrep')
+  const builtinCommand = resolveBuiltinRgPath()
-  const builtinCommand =
-    process.platform === 'win32'
-      ? path.resolve(rgRoot, `${process.arch}-win32`, 'rg.exe')
-      : path.resolve(rgRoot, `${process.arch}-${process.platform}`, 'rg')
-  const builtinExists = existsSync(builtinCommand)
   const { cmd: systemExecutablePath } = findExecutable('rg', [])
 
   return resolveRipgrepConfig({
     userWantsSystemRipgrep,
     bundledMode,
     builtinCommand,
-    builtinExists,
     systemExecutablePath,
   })
 })

src/utils/secureStorage/macOsKeychainHelpers.ts

@@ -34,8 +34,7 @@ export function getSecureStorageServiceName(
   serviceSuffix: string = '',
 ): string {
   const configDir = getClaudeConfigHomeDir()
-  const isDefaultDir =
+  const isDefaultDir = !process.env.CLAUDE_CONFIG_DIR
-    !process.env.OPENCLAUDE_CONFIG_DIR && !process.env.CLAUDE_CONFIG_DIR
 
   // Use a hash of the config dir path to create a unique but stable suffix
   // Only add suffix for non-default directories to maintain backwards compatibility

src/utils/swarm/spawnUtils.ts

@@ -117,8 +117,7 @@ const TEAMMATE_ENV_VARS = [
   'MISTRAL_BASE_URL',
   // Custom API endpoint
   'ANTHROPIC_BASE_URL',
-  // Config directory override (preferred name + legacy alias)
+  // Config directory override
-  'OPENCLAUDE_CONFIG_DIR',
   'CLAUDE_CONFIG_DIR',
   // CCR marker — teammates need this for CCR-aware code paths. Auth finds
   // its own way via /home/claude/.claude/remote/.oauth_token regardless;