release(v1.7.38-alpha): onboarding auto-heal + silent returning logins + app-store trim

- auth.rs now infers onboarding-complete from setup_complete + password_hash so
  nodes stop bouncing users through the intro wizard after browser clear / update
  / reboot; the flag self-heals to disk on next check
- frontend: "backend uncertain" no longer defaults to /onboarding/intro —
  useOnboarding returns null + callers poll / retry instead of flashing the wizard
- login sounds (synthwave, welcome voice, pop, whoosh, oomph) gated by
  isFirstInstallPhase(); typing sounds unaffected
- removed FIPS app, Nostr Relay, Nostr VPN, Routstr, Penpot from catalog,
  frontend config, Rust AppMetadata + install dispatch + install_penpot_stack;
  docker/fips-ui + docker/nostr-vpn-ui + apps/penpot dirs and 5 icons deleted;
  15 image versions deleted from tx1138, .168, gitea-local registries (.160
  Gitea was 502 at release time — follow-up)
- AIUI baked into frontend release tarball via demo/aiui/; deploy-to-target
  falls back to demo/aiui/ when the AIUI sibling checkout is missing
- prebuild hook syncs app-catalog/catalog.json → public/catalog.json so the
  two copies can no longer drift (was the source of the "apps still visible"
  bug — public/ had stale data)

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>

scripts/create-release-manifest.sh

@@ -65,13 +65,31 @@ if [ -z "$BACKEND_BINARY" ]; then
     BACKEND_BINARY="$PROJECT_ROOT/core/target/release/archipelago"
 fi
 
-# Auto-detect frontend archive
+# Auto-detect frontend archive.
+# Layout: flat tarball (`./index.html`, `./assets/…`, `./aiui/…`) so the
+# Rust updater can unpack it directly into /opt/archipelago/web-ui/.
+# Using `-C web/dist neode-ui` would produce a `neode-ui/` prefix which
+# breaks the installer and returns 403 on every fleet UI — see
+# feedback_release_tarball_layout.md.
 if [ -z "$FRONTEND_ARCHIVE" ]; then
     FRONTEND_DIST="$PROJECT_ROOT/web/dist/neode-ui"
     if [ -d "$FRONTEND_DIST" ]; then
         FRONTEND_ARCHIVE="/tmp/archipelago-frontend-${VERSION}.tar.gz"
-        echo "Creating frontend archive from $FRONTEND_DIST..."
-        tar -czf "$FRONTEND_ARCHIVE" -C "$PROJECT_ROOT/web/dist" neode-ui
+        STAGING_DIR=$(mktemp -d -t archipelago-frontend.XXXXXX)
+        echo "Staging frontend archive in $STAGING_DIR..."
+        cp -r "$FRONTEND_DIST/." "$STAGING_DIR/"
+        # Bake AIUI in so fresh installs pick it up. OTA already
+        # carries-forward the existing aiui/ if the tarball lacks one
+        # (update.rs:922), but including it here makes the tarball
+        # the single source of truth instead of relying on a side-
+        # effect of the in-place swap.
+        if [ -d "$PROJECT_ROOT/demo/aiui" ] && [ -f "$PROJECT_ROOT/demo/aiui/index.html" ]; then
+            echo "  Including AIUI from demo/aiui/"
+            cp -r "$PROJECT_ROOT/demo/aiui" "$STAGING_DIR/aiui"
+        fi
+        echo "Creating frontend archive $FRONTEND_ARCHIVE..."
+        tar -czf "$FRONTEND_ARCHIVE" -C "$STAGING_DIR" .
+        rm -rf "$STAGING_DIR"
     fi
 fi
 

scripts/deploy-to-target.sh

@@ -600,6 +600,13 @@ if [ "$LIVE" = true ]; then
         echo "$(timestamp)    Building AIUI (source newer than dist or dist missing)..."
         (cd "$AIUI_DIR" && VITE_BASE_PATH=/aiui/ pnpm build 2>&1 | tail -5) || echo "$(timestamp)    ⚠️  AIUI build failed"
     fi
+    # Fallback: if the AIUI sibling checkout is missing, use the pre-built
+    # dist shipped in this repo at demo/aiui/. That path is what we ship in
+    # the release tarball too, so local-and-fleet-update stay consistent.
+    if [ ! -f "$AIUI_DIST/index.html" ] && [ -f "$PROJECT_DIR/demo/aiui/index.html" ]; then
+        echo "$(timestamp)    AIUI sibling dist missing — using demo/aiui/ from repo"
+        AIUI_DIST="$PROJECT_DIR/demo/aiui"
+    fi
     if [ -d "$AIUI_DIST" ] && [ -f "$AIUI_DIST/index.html" ]; then
         echo "$(timestamp)    Deploying AIUI..."
         if true; then