fix(config): normalize empty security config before save/load (#1956)

Normalize missing security sections when attaching, loading, and saving
security config so existing config files without `.security.yml` can still
be updated safely. This fixes Pico channel setup for legacy/existing configs
and adds coverage for the missing security file path and unexported JSON
field behavior.

pkg/config/config.go

@@ -106,6 +106,7 @@ func (c *Config) WithSecurity(sec *SecurityConfig) *Config {
 		c.security = sec
 		return c
 	}
+	sec = normalizeSecurityConfig(sec)
 	err := applySecurityConfig(c, sec)
 	if err != nil {
 		return nil
@@ -1768,6 +1769,7 @@ func SaveConfig(path string, cfg *Config) error {
 		logger.ErrorC("config", "security is nil")
 		return fmt.Errorf("security is nil")
 	}
+	cfg.security = normalizeSecurityConfig(cfg.security)
 	// Ensure version is always set when saving
 	if cfg.Version == 0 {
 		cfg.Version = CurrentVersion

pkg/config/security.go

@@ -25,6 +25,25 @@ const (
 	SecurityConfigFile = ".security.yml"
 )
 
+func normalizeSecurityConfig(sec *SecurityConfig) *SecurityConfig {
+	if sec == nil {
+		sec = &SecurityConfig{}
+	}
+	if sec.ModelList == nil {
+		sec.ModelList = map[string]ModelSecurityEntry{}
+	}
+	if sec.Channels == nil {
+		sec.Channels = &ChannelsSecurity{}
+	}
+	if sec.Web == nil {
+		sec.Web = &WebToolsSecurity{}
+	}
+	if sec.Skills == nil {
+		sec.Skills = &SkillsSecurity{}
+	}
+	return sec
+}
+
 // SecurityConfig stores all sensitive data (API keys, tokens, secrets, passwords)
 // This data is loaded from security.yml and kept separate from the main config
 type SecurityConfig struct {
@@ -191,7 +210,7 @@ func loadSecurityConfig(securityPath string) (*SecurityConfig, error) {
 	data, err := os.ReadFile(securityPath)
 	if err != nil {
 		if os.IsNotExist(err) {
-			return &SecurityConfig{}, nil
+			return normalizeSecurityConfig(nil), nil
 		}
 		return nil, fmt.Errorf("failed to read security config: %w", err)
 	}
@@ -210,7 +229,7 @@ func loadSecurityConfig(securityPath string) (*SecurityConfig, error) {
 		return nil, err
 	}
 
-	return &sec, nil
+	return normalizeSecurityConfig(&sec), nil
 }
 
 // saveSecurityConfig saves the security configuration to security.yml

pkg/config/security_integration_test.go

@@ -17,13 +17,12 @@ import (
 
 // Test JSON unmarshal of private fields
 func TestJSONUnmarshalPrivateFields(t *testing.T) {
-	//nolint: govet
 	type testStruct struct {
 		PublicField  string `json:"public"`
-		privateField string `json:"private"`
+		privateField string
 	}
 
-	data := `{"public": "pub", "private": "priv"}`
+	data := `{"public": "pub", "privateField": "priv"}`
 	var s testStruct
 	if err := json.Unmarshal([]byte(data), &s); err != nil {
 		t.Fatalf("JSON unmarshal failed: %v", err)
@@ -35,9 +34,8 @@ func TestJSONUnmarshalPrivateFields(t *testing.T) {
 	if s.PublicField != "pub" {
 		t.Errorf("PublicField = %q, want 'pub'", s.PublicField)
 	}
-	// This should fail because privateField is unexported
-	if s.privateField != "priv" {
-		t.Logf("privateField = %q, want 'priv' - THIS IS EXPECTED TO FAIL", s.privateField)
+	if s.privateField != "" {
+		t.Errorf("privateField = %q, want empty because unexported fields are ignored", s.privateField)
 	}
 }
 

pkg/config/security_test.go

@@ -20,6 +20,9 @@ func TestSecurityConfig(t *testing.T) {
 		require.NoError(t, err)
 		assert.NotNil(t, sec)
 		assert.Empty(t, sec.ModelList)
+		assert.NotNil(t, sec.Channels)
+		assert.NotNil(t, sec.Web)
+		assert.NotNil(t, sec.Skills)
 	})
 }
 

web/backend/api/config_test.go

@@ -170,7 +170,7 @@ func setupPicoEnabledEnv(t *testing.T) (string, func()) {
 		ModelList: map[string]config.ModelSecurityEntry{
 			"custom-default": {APIKeys: []string{"sk-default"}},
 		},
-		Channels: config.ChannelsSecurity{
+		Channels: &config.ChannelsSecurity{
 			Pico: &config.PicoSecurity{Token: "test-pico-token"},
 		},
 	})

web/backend/api/pico_test.go

@@ -6,6 +6,7 @@ import (
 	"net/http"
 	"net/http/httptest"
 	"net/url"
+	"os"
 	"path/filepath"
 	"strconv"
 	"testing"
@@ -154,6 +155,44 @@ func TestEnsurePicoChannel_PreservesUserSettings(t *testing.T) {
 	}
 }
 
+func TestEnsurePicoChannel_ExistingConfigWithoutSecurityFile(t *testing.T) {
+	configPath := filepath.Join(t.TempDir(), "config.json")
+
+	cfg := config.DefaultConfig()
+	raw, err := json.Marshal(cfg)
+	if err != nil {
+		t.Fatalf("Marshal() error = %v", err)
+	}
+	if err = os.WriteFile(configPath, raw, 0o600); err != nil {
+		t.Fatalf("WriteFile() error = %v", err)
+	}
+
+	h := NewHandler(configPath)
+
+	changed, err := h.ensurePicoChannel("")
+	if err != nil {
+		t.Fatalf("ensurePicoChannel() error = %v", err)
+	}
+	if !changed {
+		t.Fatal("ensurePicoChannel() should report changed when pico is missing")
+	}
+
+	cfg, err = config.LoadConfig(configPath)
+	if err != nil {
+		t.Fatalf("LoadConfig() error = %v", err)
+	}
+
+	if !cfg.Channels.Pico.Enabled {
+		t.Error("expected Pico to be enabled after setup")
+	}
+	if cfg.Channels.Pico.Token() == "" {
+		t.Error("expected a non-empty token after setup")
+	}
+	if _, err := os.Stat(filepath.Join(filepath.Dir(configPath), config.SecurityConfigFile)); err != nil {
+		t.Fatalf("expected .security.yml to be created: %v", err)
+	}
+}
+
 func TestEnsurePicoChannel_Idempotent(t *testing.T) {
 	configPath := filepath.Join(t.TempDir(), "config.json")
 	h := NewHandler(configPath)