fix: prevent server hang and output corruption in spawn handling (#23)

- Add process 'error' event handler to catch spawn failures (e.g., yt-dlp not installed)
- Separate stdout/stderr to prevent yt-dlp warnings from corrupting parsed output
- Add try-catch for RegExp construction from YTDLP_SANITIZE_ILLEGAL_CHARS env var
- Add NaN validation for YTDLP_MAX_FILENAME_LENGTH env var
- Sync VERSION constant with package.json (0.8.4)
- Update tests for new output format and null handling
- Add version sync guidance to CLAUDE.md

CHANGELOG.md

@@ -7,10 +7,23 @@ and this project adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0
 
 ## [Unreleased]
 
+---
+
+## [0.8.4] - 2026-01-04
+
+### Fixed
+- **Critical**: Added missing process error handler in `_spawnPromise()` to prevent server hang when yt-dlp is not installed or fails to spawn ([#23](https://github.com/kevinwatt/yt-dlp-mcp/issues/23))
+- **Critical**: Fixed stdout/stderr mixing in `_spawnPromise()` that caused yt-dlp warnings to corrupt parsed output
+- Fixed VERSION constant mismatch (was `0.7.0`, now synced with package.json)
+- Added try-catch for RegExp construction from `YTDLP_SANITIZE_ILLEGAL_CHARS` env var to prevent startup crash on invalid regex
+- Added validation for `YTDLP_MAX_FILENAME_LENGTH` env var to handle NaN values gracefully
+- Fixed test expectations for search output format and metadata `creators` field null handling
+
 ### Changed
 - **Documentation**: Added warning about JavaScript runtime (deno) requirement when using cookie authentication
   - YouTube authenticated API endpoints require JS challenge solving
   - Without deno, downloads will fail with "n challenge solving failed" error
+- **Documentation**: Added version sync guidance to CLAUDE.md (package.json + src/index.mts)
 
 ---
 

CLAUDE.md

@@ -5,6 +5,9 @@ This file provides guidance to Claude Code (claude.ai/code) when working with co
 ## Development Guidelines
 
 - **Always update CHANGELOG.md** when making changes to the codebase
+- **Version updates require TWO files**:
+  1. `package.json` - line 3: `"version": "x.x.x"`
+  2. `src/index.mts` - line 24: `const VERSION = 'x.x.x'`
 
 ## Development Commands
 

package-lock.json

@@ -1,12 +1,12 @@
 {
   "name": "@kevinwatt/yt-dlp-mcp",
-  "version": "0.8.2",
+  "version": "0.8.3",
   "lockfileVersion": 3,
   "requires": true,
   "packages": {
     "": {
       "name": "@kevinwatt/yt-dlp-mcp",
-      "version": "0.8.2",
+      "version": "0.8.3",
       "license": "MIT",
       "dependencies": {
         "@modelcontextprotocol/sdk": "0.7.0",

package.json

@@ -1,6 +1,6 @@
 {
   "name": "@kevinwatt/yt-dlp-mcp",
-  "version": "0.8.3",
+  "version": "0.8.4",
   "description": "An MCP server implementation that integrates with yt-dlp, providing video and audio content download capabilities (e.g. YouTube, Facebook, Tiktok, etc.) for LLMs.",
   "keywords": [
     "mcp",

src/__tests__/metadata.test.ts

@@ -83,8 +83,9 @@ describe('Video Metadata Extraction', () => {
       if (metadata.description !== undefined) {
         expect(typeof metadata.description).toBe('string');
       }
-      if (metadata.creators !== undefined) {
+      if (metadata.creators !== undefined && metadata.creators !== null) {
-        expect(Array.isArray(metadata.creators)).toBe(true);
+        // creators can be an array or a string depending on the video
+        expect(Array.isArray(metadata.creators) || typeof metadata.creators === 'string').toBe(true);
       }
       if (metadata.timestamp !== undefined) {
         expect(typeof metadata.timestamp).toBe('number');

src/__tests__/search.test.ts

@@ -48,7 +48,7 @@ describe('Search functionality tests', () => {
       const result = await searchVideos('react tutorial', 2, 0, 'markdown', CONFIG);
 
       // Check for proper formatting
-      expect(result).toMatch(/Found \d+ videos?:/);
+      expect(result).toMatch(/Found \d+ videos? \(showing \d+\):/);
       expect(result).toMatch(/\d+\. \*\*.*\*\*/); // Numbered list with bold titles
       expect(result).toMatch(/📺 Channel: .+/);
       expect(result).toMatch(/⏱️  Duration: .+/);

src/config.ts

@@ -109,13 +109,26 @@ function loadEnvConfig(): DeepPartial<Config> {
     sanitize: {
       replaceChar: process.env.YTDLP_SANITIZE_REPLACE_CHAR,
       truncateSuffix: process.env.YTDLP_SANITIZE_TRUNCATE_SUFFIX,
-      illegalChars: process.env.YTDLP_SANITIZE_ILLEGAL_CHARS ? new RegExp(process.env.YTDLP_SANITIZE_ILLEGAL_CHARS) : undefined,
+      illegalChars: (() => {
+        if (!process.env.YTDLP_SANITIZE_ILLEGAL_CHARS) return undefined;
+        try {
+          return new RegExp(process.env.YTDLP_SANITIZE_ILLEGAL_CHARS);
+        } catch {
+          console.warn('[yt-dlp-mcp] Invalid regex in YTDLP_SANITIZE_ILLEGAL_CHARS, using default');
+          return undefined;
+        }
+      })(),
       reservedNames: process.env.YTDLP_SANITIZE_RESERVED_NAMES?.split(',')
     }
   };
-  
+
   if (process.env.YTDLP_MAX_FILENAME_LENGTH) {
-    fileConfig.maxFilenameLength = parseInt(process.env.YTDLP_MAX_FILENAME_LENGTH);
+    const parsed = parseInt(process.env.YTDLP_MAX_FILENAME_LENGTH, 10);
+    if (!isNaN(parsed) && parsed >= 5) {
+      fileConfig.maxFilenameLength = parsed;
+    } else {
+      console.warn('[yt-dlp-mcp] Invalid YTDLP_MAX_FILENAME_LENGTH, using default');
+    }
   }
   if (process.env.YTDLP_DOWNLOADS_DIR) {
     fileConfig.downloadsDir = process.env.YTDLP_DOWNLOADS_DIR;

src/index.mts

@@ -21,7 +21,7 @@ import { searchVideos } from "./modules/search.js";
 import { getVideoMetadata, getVideoMetadataSummary } from "./modules/metadata.js";
 import { getVideoComments, getVideoCommentsSummary } from "./modules/comments.js";
 
-const VERSION = '0.7.0';
+const VERSION = '0.8.4';
 
 // Response format enum
 enum ResponseFormat {

src/modules/utils.ts

@@ -91,21 +91,26 @@ export async function safeCleanup(directory: string): Promise<void> {
 export function _spawnPromise(command: string, args: string[]): Promise<string> {
   return new Promise((resolve, reject) => {
     const process = spawn(command, args);
-    let output = '';
+    let stdout = '';
+    let stderr = '';
+
+    process.on('error', (err) => {
+      reject(new Error(`Failed to spawn ${command}: ${err.message}`));
+    });
 
     process.stdout.on('data', (data) => {
-      output += data.toString();
+      stdout += data.toString();
     });
 
     process.stderr.on('data', (data) => {
-      output += data.toString();
+      stderr += data.toString();
     });
 
     process.on('close', (code) => {
       if (code === 0) {
-        resolve(output);
+        resolve(stdout);
       } else {
-        reject(new Error(`Failed with exit code: ${code}\n${output}`));
+        reject(new Error(`Failed with exit code: ${code}\n${stderr}\n${stdout}`));
       }
     });
   });