test: raise coverage 49.67% → 98.84%, fix the config that hid the gap

[chriskehayias]

The reported coverage number was wrong

vitest.config.ts set no coverage.include, so the v8 provider only instrumented files that some test had already imported. 131 of 176 source files were absent from the report entirely rather than counted as 0%. It read 83.14% while true coverage was 48.41% — and this is the report CI uploads to Codecov.

That's how src/services/familyService.ts (756 lines) and src/app/(web)/tools/layout.tsx (the /tools authorization gate) sat at zero tests without anyone seeing it.

Results

Measured on the same denominator before and after:

Metric	Before	After
Statements	49.67% (1,814/3,652)	98.84% (3,610/3,652)
Lines	50.20%	99.70% (3,363/3,373)
Branches	37.51%	92.21%
Functions	38.35%	98.81%
Test files	50	116
Test cases	812	1,535

Scope excludes vendored shadcn/ui primitives, generated MP models, build-time scripts, loading.tsx skeletons, barrels, and type-only modules.

Config changes

• coverage.include: ['src/**/*.{ts,tsx}'] — the actual fix. Worth knowing: coverage.all was removed in Vitest 5, so setting it is a type error that does nothing. include is the only lever.
• Directory exclusions now end in **. A bare 'src/components/ui/' matches nothing, which had quietly kept those files in the denominator.
• thresholds: { statements: 97, lines: 98 }, enforced by the existing test:coverage CI job. Branches and functions are deliberately unenforced — a single defensive guard can trip them, and a threshold people learn to override is worse than none. I verified the gate actually fires by setting it to an impossible value and confirming exit 1.
• vitest.config.ts → .mts. As .ts it loaded as CommonJS and Vite warned it breaks when configLoader: 'native' becomes the default. The rename exposed a second instance of the same problem: __dirname only worked because of the CJS load. As real ESM it would have thrown at config load and stopped every test from starting. Now import.meta.dirname.

npm run build was already broken on dev

tsconfig.json includes **/*.ts, next.config.ts sets no ignoreBuildErrors, and CI never runs next build — so two committed test files failed type checking while CI stayed green.

Their fixtures built CommunicationInfo / MessageInfo / FileUploadParams values from raw MP column names (Author_User_ID, From_Contact) instead of the DTO fields the helper requires. The tests passed because the mocks never inspected the missing fields. Fixtures now carry explicit type annotations so the compiler enforces the shape. Build succeeds.

Runner output: 1,507 lines → 17, zero warnings

• Barcode tests mocked react-pdf's View as the string 'View', which React read as a capitalised unknown tag — two warnings per element, 797 lines for one 65-bar barcode. Now rpdf-view; the dash matters, since any undashed unknown tag still draws "unrecognized in this browser".
• Added console spies to the 15 test files that deliberately drive error paths. The MP logger is unconditional by design, so those were expected logs plus stack traces. The spies use mockImplementation, so they still record and assertions on logged content keep working.

One source fix (14 lines)

Select fields in the group wizard and Add/Edit Family passed value={... : undefined}, leaving them uncontrolled until first selection and logging a React controlled/uncontrolled warning.

Silencing that in tests would have hidden a real bug: while a field is uncontrolled, React state is not the source of truth for it, so form.reset() between wizard runs isn't guaranteed to clear the trigger. Changed to "", Radix's documented "no selection" value. Diff is exactly 14 lines, nothing else.

Review pointers

113 files, but only a handful need real attention:

• vitest.config.mts — the config contract and thresholds
• the 5 .tsx source files — 14 identical one-line changes
• helper.test.ts / provider.test.ts — the corrected fixtures
• everything else is new *.test.* files and docs

TODOs: 8 opened, 4 resolved

9 open — 3 high, all found by reading code while writing tests for it:

• Filter injection shape — FamilyService interpolates client-supplied envelopeNo/donorId into MP $filter strings with no validation; the only filters in that file lacking a validatePositiveInt guard.
• Silent field loss — removeGroup guards groupedFields but not groupOrder, so a non-empty group can be stripped from the order while its fields remain. buildSavePayload then drops them. Real MP page-config data loss, no error surfaced.
• Address PII into logs — mergeTemplate logs the raw docxtemplater error, which attaches the live merge scope (names, addresses).

Plus 4 medium (incl. no type-check gate in CI) and 2 low. Docs updated: CLAUDE.md, DECISIONS.md, testing references, new facts snapshot.

Verification

Gate	Result
npm run test:run	exit 0 — 116 files, 1,535 tests, 17 lines, no warnings
npm run test:coverage	exit 0 — thresholds pass
npx tsc --noEmit	0 errors
npx eslint .	0 problems
npm run build	exit 0

🤖 Generated with Claude Code

[codecov]

Codecov Report

✅ All modified and coverable lines are covered by tests.

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