v0.15.5: Fix startup hub report — Push() returns real errors, startup retries 3x with 15s delay

CHANGELOG.md

@@ -1,5 +1,14 @@
 ## Changelog
 
+### What was just completed (2026-02-19 session 55)
+- **v0.15.5 — Fix startup hub report silently failing:**
+
+  `Push()` now returns actual errors instead of always `nil`. Previously, push failures were logged internally but the caller could never detect them, leading to a misleading `[INFO] Startup hub report sent` log even when the push actually failed (e.g., hub returning HTTP 503 during simultaneous deployment). Removed the "Never returns error to caller" behavior: marshal error returns a wrapped error, and after 3 failed retries the error is returned to the caller (the internal `[WARN]` log before `return nil` is gone).
+
+  Startup hub push now retries 3 times with 15-second delays between outer attempts, giving the hub time to come up when both are deployed together. Each outer attempt uses `Push()`'s own internal 3-retry logic (5s backoff), so the hub gets up to ~40s total to become ready. If all 3 outer attempts fail, logs a clear warning with the next scheduled push interval.
+
+  **Files modified (2):** `internal/report/pusher.go`, `cmd/controller/main.go`
+
 ### What was just completed (2026-02-19 session 54)
 - **v0.15.4 (controller) + hub v0.1.6 — Hub reporting improvements:**
 

controller/cmd/controller/main.go

@@ -290,10 +290,20 @@ func main() {
 		if hubPusher != nil {
 			if cfg.Hub.Enabled {
 				r := report.BuildReport(cfg, stackMgr, backupMgr, cpuCollector, metricsStore, Version, sett.GetStoragePaths())
-				if err := hubPusher.Push(r); err != nil {
-					logger.Printf("[WARN] Startup hub report failed: %v", err)
-				} else {
-					logger.Println("[INFO] Startup hub report sent")
+				var pushErr error
+				for attempt := 1; attempt <= 3; attempt++ {
+					pushErr = hubPusher.Push(r)
+					if pushErr == nil {
+						logger.Println("[INFO] Startup hub report sent")
+						break
+					}
+					logger.Printf("[WARN] Startup hub report attempt %d/3 failed: %v", attempt, pushErr)
+					if attempt < 3 {
+						time.Sleep(15 * time.Second)
+					}
+				}
+				if pushErr != nil {
+					logger.Printf("[WARN] Startup hub report failed after 3 attempts — next scheduled push in %s", cfg.Hub.PushInterval)
 				}
 			} else {
 				// Send a minimal "disabled" notification so hub knows reporting is intentionally off

controller/internal/report/pusher.go

@@ -36,7 +36,6 @@ func NewPusher(cfg *config.HubConfig, logger *log.Logger) *Pusher {
 }
 
 // Push sends a report to the hub. Retries 3 times with 5s backoff.
-// Never returns error to caller — push failures should not affect controller operation.
 func (p *Pusher) Push(report *Report) error {
 	if !p.enabled {
 		return nil
@@ -44,8 +43,7 @@ func (p *Pusher) Push(report *Report) error {
 
 	data, err := json.Marshal(report)
 	if err != nil {
-		p.logger.Printf("[WARN] Hub report marshal failed: %v", err)
-		return nil
+		return fmt.Errorf("marshal report: %w", err)
 	}
 
 	url := p.hubURL + "/api/v1/report"
@@ -81,8 +79,7 @@ func (p *Pusher) Push(report *Report) error {
 		lastErr = fmt.Errorf("HTTP %d", resp.StatusCode)
 	}
 
-	p.logger.Printf("[WARN] Hub report push failed after 3 attempts: %v", lastErr)
-	return nil
+	return fmt.Errorf("hub push failed after 3 attempts: %w", lastErr)
 }
 
 // PushOnce sends a single report regardless of the enabled flag.