feat: modernize Electron build process with Vite-based CSS injection

- Replace manual CSS injection hack with Vite plugin
- Configure Vite to handle both main process and renderer builds
- Update build scripts to work with proper Vite output structure
- Remove fix-inject-css.js post-build script
- Update BUILDING.md documentation
- Add build-modernization-context.md for future reference

Technical changes:
- vite.config.electron.mts: Add electron-css-injection plugin and proper output config
- scripts/build-electron.js: Simplify to work with Vite-generated files
- BUILDING.md: Update Electron build documentation
- doc/build-modernization-context.md: Document context and decisions

Security/maintenance improvements:
- Eliminate manual file manipulation hacks
- Ensure deterministic, reproducible builds
- Centralize build logic in Vite configuration
- Improve developer experience and CI/CD compatibility

Author: Matthew Raymer

BUILDING.md

@@ -634,3 +634,19 @@ For iOS deep links, configure the URL scheme in Xcode:
 | `web` | web | true | false | Standard web browser |
 | `capacitor` | capacitor | false | true | Mobile app (iOS/Android) |
 | `electron` | electron | false | true | Desktop app (Windows/macOS/Linux) |
+
+## Electron Build: CSS Injection
+
+The Electron build now uses Vite's built-in CSS handling with a custom plugin (`electron-css-injection`) that automatically injects CSS links into the generated `index.html` file. This replaces the previous manual CSS injection script.
+
+**Plugin:** `vite.config.electron.mts` - `electron-css-injection` plugin
+
+**Features:**
+- Automatically detects and injects CSS files generated by Vite
+- Ensures proper relative paths for Electron builds
+- Handles multiple CSS files if present
+- Provides detailed logging during build process
+
+**No manual intervention required** - CSS injection is handled automatically during the Vite build process.
+
+**Author:** Matthew Raymer

doc/build-modernization-context.md

@@ -0,0 +1,51 @@
+# TimeSafari Build Modernization Context
+
+**Author:** Matthew Raymer
+
+## Motivation
+- Eliminate manual hacks and post-build scripts for Electron builds
+- Ensure maintainability, reproducibility, and security of build outputs
+- Unify build, test, and deployment scripts for developer experience and CI/CD
+
+## Key Technical Decisions
+- **Vite is the single source of truth for build output**
+  - All Electron build output (main process, preload, renderer HTML/CSS/JS) is managed by `vite.config.electron.mts`
+- **CSS injection for Electron is handled by a Vite plugin**
+  - No more manual HTML/CSS edits or post-build scripts
+- **Build scripts are unified and robust**
+  - Use `./scripts/build-electron.sh` for all Electron builds
+  - No more `fix-inject-css.js` or similar hacks
+- **Output structure is deterministic and ASAR-friendly**
+  - Main process: `dist-electron/main.js`
+  - Preload: `dist-electron/preload.js`
+  - Renderer assets: `dist-electron/www/` (HTML, CSS, JS)
+
+## Security & Maintenance Checklist
+- [x] All scripts and configs are committed and documented
+- [x] No manual file hacks remain
+- [x] All build output is deterministic and reproducible
+- [x] No sensitive data is exposed in the build process
+- [x] Documentation (`BUILDING.md`) is up to date
+
+## How to Build Electron
+1. Run:
+   ```bash
+   ./scripts/build-electron.sh
+   ```
+2. Output will be in `dist-electron/`:
+   - `main.js`, `preload.js` in root
+   - `www/` contains all renderer assets
+3. No manual post-processing is required
+
+## Customization
+- **Vite config:** All build output and asset handling is controlled in `vite.config.electron.mts`
+- **CSS/HTML injection:** Use Vite plugins (see `electron-css-injection` in the config) for further customization
+- **Build scripts:** All orchestration is in `scripts/` and documented in `BUILDING.md`
+
+## For Future Developers
+- Always use Vite plugins/config for build output changes
+- Never manually edit built files or inject assets post-build
+- Keep documentation and scripts in sync with the build process
+
+---
+This file documents the context and rationale for the build modernization and should be included in the repository for onboarding and future reference. 

scripts/build-electron.js

@@ -12,59 +12,53 @@ if (!fs.existsSync(wwwPath)) {
   fs.mkdirSync(wwwPath, { recursive: true });
 }
 
-// Create a platform-specific index.html for Electron
-const initialIndexContent = `<!DOCTYPE html>
-<html lang="">
-  <head>
-    <meta charset="utf-8">
-    <meta http-equiv="X-UA-Compatible" content="IE=edge">
-    <meta name="viewport" content="width=device-width,initial-scale=1.0,viewport-fit=cover">
-    <link rel="icon" href="./favicon.ico">
-    <title>TimeSafari</title>
-  </head>
-  <body>
-    <noscript>
-      <strong>We're sorry but TimeSafari doesn't work properly without JavaScript enabled. Please enable it to continue.</strong>
-    </noscript>
-    <div id="app"></div>
-    <script type="module" src="./main.electron.js"></script>
-  </body>
-</html>`;
-
-// Write the Electron-specific index.html
-fs.writeFileSync(path.join(wwwPath, 'index.html'), initialIndexContent);
-
-// Copy only necessary assets from web build
-const webDistPath = path.join(__dirname, '..', 'dist');
-if (fs.existsSync(webDistPath)) {
-  // Copy assets directory
-  const assetsSrc = path.join(webDistPath, 'assets');
-  const assetsDest = path.join(wwwPath, 'assets');
-  if (fs.existsSync(assetsSrc)) {
-    fs.cpSync(assetsSrc, assetsDest, { recursive: true });
-  }
+// Copy the Vite-built index.html to www directory
+const viteIndexPath = path.join(electronDistPath, 'index.html');
+const wwwIndexPath = path.join(wwwPath, 'index.html');
+
+if (fs.existsSync(viteIndexPath)) {
+  console.log('Copying Vite-built index.html to www directory...');
+  fs.copyFileSync(viteIndexPath, wwwIndexPath);
+  
+  // Remove the original index.html from dist-electron root
+  fs.unlinkSync(viteIndexPath);
+  console.log('Moved index.html to www directory');
+} else {
+  console.error('Vite-built index.html not found at:', viteIndexPath);
+  process.exit(1);
+}
+
+// Copy assets directory if it exists in dist-electron
+const assetsSrc = path.join(electronDistPath, 'assets');
+const assetsDest = path.join(wwwPath, 'assets');
 
-  // Copy favicon
-  const faviconSrc = path.join(webDistPath, 'favicon.ico');
-  if (fs.existsSync(faviconSrc)) {
-    fs.copyFileSync(faviconSrc, path.join(wwwPath, 'favicon.ico'));
+if (fs.existsSync(assetsSrc)) {
+  console.log('Moving assets directory to www...');
+  if (fs.existsSync(assetsDest)) {
+    fs.rmSync(assetsDest, { recursive: true, force: true });
   }
+  fs.renameSync(assetsSrc, assetsDest);
+  console.log('Moved assets directory to www');
 }
 
-// Remove service worker files
+// Copy favicon if it exists
+const faviconSrc = path.join(electronDistPath, 'favicon.ico');
+const faviconDest = path.join(wwwPath, 'favicon.ico');
+
+if (fs.existsSync(faviconSrc)) {
+  console.log('Moving favicon to www...');
+  fs.renameSync(faviconSrc, faviconDest);
+  console.log('Moved favicon to www');
+}
+
+// Remove service worker files from www directory
 const swFilesToRemove = [
   'sw.js',
   'sw.js.map',
   'workbox-*.js',
   'workbox-*.js.map',
   'registerSW.js',
-  'manifest.webmanifest',
-  '**/workbox-*.js',
-  '**/workbox-*.js.map',
-  '**/sw.js',
-  '**/sw.js.map',
-  '**/registerSW.js',
-  '**/manifest.webmanifest'
+  'manifest.webmanifest'
 ];
 
 console.log('Removing service worker files...');
@@ -84,14 +78,13 @@ swFilesToRemove.forEach(pattern => {
 });
 
 // Also check and remove from assets directory
-const assetsPath = path.join(wwwPath, 'assets');
-if (fs.existsSync(assetsPath)) {
+if (fs.existsSync(assetsDest)) {
   swFilesToRemove.forEach(pattern => {
-    const files = fs.readdirSync(assetsPath).filter(file => 
+    const files = fs.readdirSync(assetsDest).filter(file => 
       file.match(new RegExp(pattern.replace(/\*/g, '.*')))
     );
     files.forEach(file => {
-      const filePath = path.join(assetsPath, file);
+      const filePath = path.join(assetsDest, file);
       console.log(`Removing ${filePath}`);
       try {
         fs.unlinkSync(filePath);
@@ -102,60 +95,54 @@ if (fs.existsSync(assetsPath)) {
   });
 }
 
-// Modify index.html to remove service worker registration
-const indexPath = path.join(wwwPath, 'index.html');
-if (fs.existsSync(indexPath)) {
-  console.log('Modifying index.html to remove service worker registration...');
-  let indexContent = fs.readFileSync(indexPath, 'utf8');
-  
-  // Remove service worker registration script
-  indexContent = indexContent
-    .replace(/<script[^>]*id="vite-plugin-pwa:register-sw"[^>]*><\/script>/g, '')
-    .replace(/<script[^>]*registerServiceWorker[^>]*><\/script>/g, '')
-    .replace(/<link[^>]*rel="manifest"[^>]*>/g, '')
-    .replace(/<link[^>]*rel="serviceworker"[^>]*>/g, '')
-    .replace(/navigator\.serviceWorker\.register\([^)]*\)/g, '')
-    .replace(/if\s*\(\s*['"]serviceWorker['"]\s*in\s*navigator\s*\)\s*{[^}]*}/g, '');
-  
-  fs.writeFileSync(indexPath, indexContent);
-  console.log('Successfully modified index.html');
-}
+// Verify the final index.html structure
+const finalIndexContent = fs.readFileSync(wwwIndexPath, 'utf8');
+console.log('Final index.html structure:');
+console.log('- Has CSS link:', finalIndexContent.includes('<link rel="stylesheet"'));
+console.log('- Has main script:', finalIndexContent.includes('main.electron.js'));
+console.log('- No service worker references:', !finalIndexContent.includes('serviceWorker'));
 
-// Fix asset paths
-console.log('Fixing asset paths in index.html...');
-let modifiedIndexContent = fs.readFileSync(indexPath, 'utf8');
-modifiedIndexContent = modifiedIndexContent
-  .replace(/\/assets\//g, './assets/')
-  .replace(/href="\//g, 'href="./')
-  .replace(/src="\//g, 'src="./');
+// Copy main process files to the correct location
+console.log('Setting up main process files...');
 
-fs.writeFileSync(indexPath, modifiedIndexContent);
+// The main process files are already in the correct location
+// Just verify they exist and are ready
+const mainPath = path.join(electronDistPath, 'main.js');
+const preloadPath = path.join(electronDistPath, 'preload.js');
 
-// Verify no service worker references remain
-const finalContent = fs.readFileSync(indexPath, 'utf8');
-if (finalContent.includes('serviceWorker') || finalContent.includes('workbox')) {
-  console.warn('Warning: Service worker references may still exist in index.html');
+if (fs.existsSync(mainPath)) {
+  console.log('Main process file ready at:', mainPath);
+} else {
+  console.error('Main process file not found at:', mainPath);
+  process.exit(1);
 }
 
-// Check for remaining /assets/ paths
-console.log('After path fixing, checking for remaining /assets/ paths:', finalContent.includes('/assets/'));
-console.log('Sample of fixed content:', finalContent.substring(0, 500));
-    
-console.log('Copied and fixed web files in:', wwwPath);
-
-// Copy main process files
-console.log('Copying main process files...');
-
-// Copy the main process file instead of creating a template
-const mainSrcPath = path.join(__dirname, '..', 'dist-electron', 'main.js');
-const mainDestPath = path.join(electronDistPath, 'main.js');
-
-if (fs.existsSync(mainSrcPath)) {
-  fs.copyFileSync(mainSrcPath, mainDestPath);
-  console.log('Copied main process file successfully');
+if (fs.existsSync(preloadPath)) {
+  console.log('Preload script ready at:', preloadPath);
 } else {
-  console.error('Main process file not found at:', mainSrcPath);
-  process.exit(1);
+  console.warn('Preload script not found at:', preloadPath);
 }
 
+// Clean up any remaining files in dist-electron root (except main.js, preload.js, and www directory)
+const remainingFiles = fs.readdirSync(electronDistPath);
+remainingFiles.forEach(file => {
+  if (file !== 'main.js' && file !== 'preload.js' && file !== 'www') {
+    const filePath = path.join(electronDistPath, file);
+    console.log(`Removing remaining file: ${file}`);
+    try {
+      if (fs.statSync(filePath).isDirectory()) {
+        fs.rmSync(filePath, { recursive: true, force: true });
+      } else {
+        fs.unlinkSync(filePath);
+      }
+    } catch (err) {
+      console.warn(`Could not remove ${filePath}:`, err.message);
+    }
+  }
+});
+
 console.log('Electron build process completed successfully');
+console.log('Final structure:');
+console.log('- Main process:', path.join(electronDistPath, 'main.js'));
+console.log('- Preload script:', path.join(electronDistPath, 'preload.js'));
+console.log('- Web assets:', path.join(electronDistPath, 'www'));

src/main.electron.ts

@@ -1,3 +1,4 @@
+import './assets/styles/tailwind.css';
 import { initializeApp } from "./main.common";
 import { logger } from "./utils/logger";
 

vite.config.electron.mts

@@ -10,14 +10,30 @@ export default defineConfig(async () => {
       outDir: 'dist-electron',
       rollupOptions: {
         input: {
+          // Main process entry points
           main: path.resolve(__dirname, 'src/electron/main.ts'),
           preload: path.resolve(__dirname, 'src/electron/preload.js'),
+          // Renderer process entry point (the web app)
+          app: path.resolve(__dirname, 'index.html'),
         },
         external: ['electron'],
         output: {
           format: 'cjs',
-          entryFileNames: '[name].js',
-          assetFileNames: 'assets/[name].[ext]',
+          entryFileNames: (chunkInfo) => {
+            // Use different formats for main process vs renderer
+            if (chunkInfo.name === 'main' || chunkInfo.name === 'preload') {
+              return '[name].js';
+            }
+            return 'assets/[name].[hash].js';
+          },
+          assetFileNames: (assetInfo) => {
+            // Keep main process files in root, others in assets
+            if (assetInfo.name === 'main.js' || assetInfo.name === 'preload.js') {
+              return '[name].[ext]';
+            }
+            return 'assets/[name].[hash].[ext]';
+          },
+          chunkFileNames: 'assets/[name].[hash].js',
         },
       },
       target: 'node18',
@@ -93,6 +109,40 @@ export default defineConfig(async () => {
           }
           return null;
         }
+      },
+      {
+        name: 'electron-css-injection',
+        enforce: 'post',
+        generateBundle(options, bundle) {
+          // Find the main CSS file
+          const cssAsset = Object.values(bundle).find(
+            (asset: any) => asset.type === 'asset' && asset.fileName?.endsWith('.css')
+          ) as any;
+          
+          if (cssAsset) {
+            // Find the HTML file and inject CSS link
+            const htmlAsset = Object.values(bundle).find(
+              (asset: any) => asset.type === 'asset' && asset.fileName?.endsWith('.html')
+            ) as any;
+            
+            if (htmlAsset) {
+              const cssHref = `./${cssAsset.fileName}`;
+              const cssLink = `    <link rel="stylesheet" href="${cssHref}">\n`;
+              
+              // Check if CSS link already exists
+              if (!htmlAsset.source.includes(cssHref)) {
+                // Inject CSS link after the title tag
+                htmlAsset.source = htmlAsset.source.replace(
+                  /(<title>.*?<\/title>)/,
+                  `$1\n${cssLink}`
+                );
+                console.log(`[electron-css-injection] Injected CSS link: ${cssHref}`);
+              } else {
+                console.log(`[electron-css-injection] CSS link already present: ${cssHref}`);
+              }
+            }
+          }
+        }
       }
     ],
     ssr: {

vite.config.electron.renderer.mts

@@ -14,12 +14,14 @@ export default defineConfig({
     outDir: 'dist-electron/www',
     emptyOutDir: false,
     assetsDir: 'assets',
+    cssCodeSplit: false,
     rollupOptions: {
       input: path.resolve(__dirname, 'src/main.electron.ts'),
       output: {
         entryFileNames: 'main.electron.js',
         assetFileNames: 'assets/[name]-[hash][extname]',
-        chunkFileNames: 'assets/[name]-[hash].js'
+        chunkFileNames: 'assets/[name]-[hash].js',
+        manualChunks: undefined
       }
     },
     commonjsOptions: {