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CI: darwin-26-aarch64 test-bun fails on most PR builds with 'buildkite-agent artifact download timed out after 120s' #33116

Description

@robobun

Summary

The :darwin: 26 aarch64 - test-bun Buildkite jobs are failing on most PR builds. The runner never starts a single test; it fails downloading the build artifact:

Error: buildkite-agent artifact download timed out after 120s for step 'darwin-aarch64-build-bun'. Refusing to continue with a partial download (would silently fall back to the wrong binary).
    at getExecPathFromBuildKite (file:///Users/administrator/Library/Services/buildkite-agent/builds/darwin-aarch64-26-5-1-1/bun/bun/scripts/runner.node.mjs:2182:13)
    at async runTests (.../scripts/runner.node.mjs:481:16)

Scope

Of the 30 most recent failed/failing builds on the bun pipeline, 22 have a failed :darwin: 26 aarch64 - test-bun job, across unrelated branches. All of them hit the same artifact download timeout:

build branch
67012 farm/fc45f163/react-compiler-hoisting-overreach
67008 farm/833a1f2f/win-appcontainer-paths
67007 claude/json-structural-index
67004 claude/node-http-http2-compat
66987 claude/navigator-clipboard-readtext-writetext
66982 farm/dc5e99a7/serve-route-target-normalization
66979 farm/9a83c90d/fix-symlink-fd-cache
66976 farm/e3947f67/bump-ci-service-containers
66971 farm/ed7cafd7/node-sqlite
66968 claude/port-node-inspector-tests
... (12 more)

I saw it reproduce on two consecutive builds of the same PR (66995 and 67012), both on the agent darwin-aarch64-26-5-1-1, about 35 minutes apart. So it is not a one-off blip.

Likely causes

  • The darwin-aarch64-26 agent fleet (or just darwin-aarch64-26-5-1-1) has slow or broken connectivity to the Buildkite artifact store, so the 120s download budget in scripts/runner.node.mjs:getExecPathFromBuildKite is not enough.
  • Or the darwin-aarch64-build-bun artifacts are larger or slower to serve than they used to be.

Impact

Every PR that lands on an affected agent goes red on a lane that ran zero tests, which both hides real failures and blocks merges. The job does not get an automatic Buildkite retry (exit status 1 from the runner), so each occurrence needs a manual "Retry job" click.

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