Bug Description

When CLAUDE_CONFIG_DIR is set to a non-default location (e.g., ~/.config/claude-code/ instead of ~/.claude/), the Claude subprocess fails to authenticate because CLAUDE_CONFIG_DIR is not included in the subprocess environment allowlist.

This results in "Not logged in - Please run login" errors in the Web UI, even when the user is fully authenticated via claude auth status.

Root Cause

packages/core/src/utils/env-allowlist.ts defines SUBPROCESS_ENV_ALLOWLIST — the set of env vars passed to Claude Code subprocesses. CLAUDE_CONFIG_DIR is missing from this list, so when a user has their Claude config in a non-default directory, the subprocess falls back to ~/.claude/ and can't find credentials.

Steps to Reproduce

1. Set CLAUDE_CONFIG_DIR to a non-default path (e.g., ~/.config/claude-code/)
2. Authenticate with claude /login
3. Start Archon with bun run dev
4. Send a message via the Web UI
5. Observe "Not logged in" error

Fix

Add 'CLAUDE_CONFIG_DIR' to the SUBPROCESS_ENV_ALLOWLIST in packages/core/src/utils/env-allowlist.ts, alongside the other Claude auth/config variables:

  // Claude auth and config
+ 'CLAUDE_CONFIG_DIR',
  'CLAUDE_USE_GLOBAL_AUTH',
  'CLAUDE_API_KEY',

Environment

• macOS (Darwin)
• Claude Code 2.1.101
• Auth method: Claude Max (OAuth via claude.ai)
• CLAUDE_CONFIG_DIR=/Users/.../.config/claude-code