feat: cross-build Windows ZIP from Linux CI runner

Replace Windows runner requirement with cross-compilation:
download Windows embedded Python + win_amd64 wheels from PyPI,
package into the same ZIP structure as build-dist.ps1.

All 4 release jobs now run on ubuntu-latest.

.gitea/workflows/release.yml

@@ -6,23 +6,69 @@ on:
       - 'v*'
 
 jobs:
+  # ── Create the release first (shared by all build jobs) ────
+  create-release:
+    runs-on: ubuntu-latest
+    outputs:
+      release_id: ${{ steps.create.outputs.release_id }}
+    steps:
+      - name: Create Gitea release
+        id: create
+        env:
+          GITEA_TOKEN: ${{ secrets.GITEA_TOKEN }}
+        run: |
+          TAG="${{ gitea.ref_name }}"
+          BASE_URL="${{ gitea.server_url }}/api/v1/repos/${{ gitea.repository }}"
+
+          IS_PRE="false"
+          if echo "$TAG" | grep -qE '(alpha|beta|rc)'; then
+            IS_PRE="true"
+          fi
+
+          RELEASE=$(curl -s -X POST "$BASE_URL/releases" \
+            -H "Authorization: token $GITEA_TOKEN" \
+            -H "Content-Type: application/json" \
+            -d "{
+              \"tag_name\": \"$TAG\",
+              \"name\": \"LedGrab $TAG\",
+              \"body\": \"## Downloads\\n\\n| Platform | File | How to run |\\n|----------|------|------------|\\n| Windows | \`LedGrab-${TAG}-win-x64.zip\` | Unzip → run \`LedGrab.bat\` → open http://localhost:8080 |\\n| Linux | \`LedGrab-${TAG}-linux-x64.tar.gz\` | Extract → run \`./run.sh\` → open http://localhost:8080 |\\n| Docker | See below | \`docker pull\` → \`docker run\` |\\n\\n### Docker\\n\\n\`\`\`bash\\ndocker pull ${{ gitea.server_url }}/${{ gitea.repository }}:${TAG}\\ndocker run -d -p 8080:8080 ${{ gitea.server_url }}/${{ gitea.repository }}:${TAG}\\n\`\`\`\",
+              \"draft\": false,
+              \"prerelease\": $IS_PRE
+            }")
+
+          RELEASE_ID=$(echo "$RELEASE" | python3 -c "import sys,json; print(json.load(sys.stdin)['id'])")
+          echo "release_id=$RELEASE_ID" >> "$GITHUB_OUTPUT"
+          echo "Created release ID: $RELEASE_ID"
+
+  # ── Windows portable ZIP (cross-built from Linux) ─────────
   build-windows:
-    runs-on: windows-latest
+    needs: create-release
+    runs-on: ubuntu-latest
     steps:
       - name: Checkout
         uses: actions/checkout@v4
         with:
           fetch-depth: 0
 
+      - name: Setup Python
+        uses: actions/setup-python@v5
+        with:
+          python-version: '3.11'
+
       - name: Setup Node.js
         uses: actions/setup-node@v4
         with:
           node-version: '20'
 
-      - name: Build portable distribution
-        shell: pwsh
+      - name: Install system dependencies
         run: |
-          .\build-dist.ps1 -Version "${{ gitea.ref_name }}"
+          sudo apt-get update
+          sudo apt-get install -y --no-install-recommends zip libportaudio2
+
+      - name: Cross-build Windows distribution
+        run: |
+          chmod +x build-dist-windows.sh
+          ./build-dist-windows.sh "${{ gitea.ref_name }}"
 
       - name: Upload build artifact
         uses: actions/upload-artifact@v3
@@ -31,44 +77,126 @@ jobs:
           path: build/LedGrab-*.zip
           retention-days: 90
 
-      - name: Create Gitea release
-        shell: pwsh
+      - name: Attach ZIP to release
         env:
           GITEA_TOKEN: ${{ secrets.GITEA_TOKEN }}
         run: |
-          $tag = "${{ gitea.ref_name }}"
-          $zipFile = Get-ChildItem "build\LedGrab-*.zip" | Select-Object -First 1
-          if (-not $zipFile) { throw "ZIP not found" }
+          TAG="${{ gitea.ref_name }}"
+          RELEASE_ID="${{ needs.create-release.outputs.release_id }}"
+          BASE_URL="${{ gitea.server_url }}/api/v1/repos/${{ gitea.repository }}"
+          ZIP_FILE=$(ls build/LedGrab-*.zip | head -1)
+          ZIP_NAME=$(basename "$ZIP_FILE")
 
-          $baseUrl = "${{ gitea.server_url }}/api/v1/repos/${{ gitea.repository }}"
-          $headers = @{
-            "Authorization" = "token $env:GITEA_TOKEN"
-            "Content-Type"  = "application/json"
-          }
+          curl -s -X POST \
+            "$BASE_URL/releases/$RELEASE_ID/assets?name=$ZIP_NAME" \
+            -H "Authorization: token $GITEA_TOKEN" \
+            -H "Content-Type: application/octet-stream" \
+            --data-binary "@$ZIP_FILE"
 
-          # Create release
-          $body = @{
-            tag_name   = $tag
-            name       = "LedGrab $tag"
-            body       = "Portable Windows build — unzip, run ``LedGrab.bat``, open http://localhost:8080"
-            draft      = $false
-            prerelease = ($tag -match '(alpha|beta|rc)')
-          } | ConvertTo-Json
+          echo "Uploaded: $ZIP_NAME"
 
-          $release = Invoke-RestMethod -Method Post `
-            -Uri "$baseUrl/releases" `
-            -Headers $headers -Body $body
+  # ── Linux tarball ──────────────────────────────────────────
+  build-linux:
+    needs: create-release
+    runs-on: ubuntu-latest
+    steps:
+      - name: Checkout
+        uses: actions/checkout@v4
+        with:
+          fetch-depth: 0
 
-          Write-Host "Created release: $($release.html_url)"
+      - name: Setup Python
+        uses: actions/setup-python@v5
+        with:
+          python-version: '3.11'
 
-          # Upload ZIP asset
-          $uploadHeaders = @{
-            "Authorization" = "token $env:GITEA_TOKEN"
-          }
-          $uploadUrl = "$baseUrl/releases/$($release.id)/assets?name=$($zipFile.Name)"
-          Invoke-RestMethod -Method Post -Uri $uploadUrl `
-            -Headers $uploadHeaders `
-            -ContentType "application/octet-stream" `
-            -InFile $zipFile.FullName
+      - name: Setup Node.js
+        uses: actions/setup-node@v4
+        with:
+          node-version: '20'
 
-          Write-Host "Uploaded: $($zipFile.Name)"
+      - name: Install system dependencies
+        run: |
+          sudo apt-get update
+          sudo apt-get install -y --no-install-recommends libportaudio2
+
+      - name: Build Linux distribution
+        run: |
+          chmod +x build-dist.sh
+          ./build-dist.sh "${{ gitea.ref_name }}"
+
+      - name: Upload build artifact
+        uses: actions/upload-artifact@v3
+        with:
+          name: LedGrab-${{ gitea.ref_name }}-linux-x64
+          path: build/LedGrab-*.tar.gz
+          retention-days: 90
+
+      - name: Attach tarball to release
+        env:
+          GITEA_TOKEN: ${{ secrets.GITEA_TOKEN }}
+        run: |
+          TAG="${{ gitea.ref_name }}"
+          RELEASE_ID="${{ needs.create-release.outputs.release_id }}"
+          BASE_URL="${{ gitea.server_url }}/api/v1/repos/${{ gitea.repository }}"
+          TAR_FILE=$(ls build/LedGrab-*.tar.gz | head -1)
+          TAR_NAME=$(basename "$TAR_FILE")
+
+          curl -s -X POST \
+            "$BASE_URL/releases/$RELEASE_ID/assets?name=$TAR_NAME" \
+            -H "Authorization: token $GITEA_TOKEN" \
+            -H "Content-Type: application/octet-stream" \
+            --data-binary "@$TAR_FILE"
+
+          echo "Uploaded: $TAR_NAME"
+
+  # ── Docker image ───────────────────────────────────────────
+  build-docker:
+    needs: create-release
+    runs-on: ubuntu-latest
+    steps:
+      - name: Checkout
+        uses: actions/checkout@v4
+        with:
+          fetch-depth: 0
+
+      - name: Set up Docker Buildx
+        uses: docker/setup-buildx-action@v3
+
+      - name: Login to Gitea Container Registry
+        uses: docker/login-action@v3
+        with:
+          registry: ${{ gitea.server_url }}
+          username: ${{ gitea.actor }}
+          password: ${{ secrets.GITEA_TOKEN }}
+
+      - name: Extract version metadata
+        id: meta
+        run: |
+          TAG="${{ gitea.ref_name }}"
+          VERSION="${TAG#v}"
+          REGISTRY="${{ gitea.server_url }}/${{ gitea.repository }}"
+          # Lowercase the registry path (Docker requires it)
+          REGISTRY=$(echo "$REGISTRY" | tr '[:upper:]' '[:lower:]' | sed 's|https\?://||')
+
+          echo "version=$VERSION" >> "$GITHUB_OUTPUT"
+          echo "registry=$REGISTRY" >> "$GITHUB_OUTPUT"
+
+          # Build tag list: version + latest (only for stable releases)
+          TAGS="$REGISTRY:$TAG,$REGISTRY:$VERSION"
+          if ! echo "$TAG" | grep -qE '(alpha|beta|rc)'; then
+            TAGS="$TAGS,$REGISTRY:latest"
+          fi
+          echo "tags=$TAGS" >> "$GITHUB_OUTPUT"
+
+      - name: Build and push Docker image
+        uses: docker/build-push-action@v5
+        with:
+          context: ./server
+          push: true
+          tags: ${{ steps.meta.outputs.tags }}
+          labels: |
+            org.opencontainers.image.version=${{ steps.meta.outputs.version }}
+            org.opencontainers.image.revision=${{ gitea.sha }}
+          cache-from: type=gha
+          cache-to: type=gha,mode=max

build-dist-windows.sh

@@ -0,0 +1,274 @@
+#!/usr/bin/env bash
+#
+# Cross-build a portable Windows distribution of LedGrab from Linux.
+#
+# Downloads Windows embedded Python and win_amd64 wheels — no Wine or
+# Windows runner needed. Produces the same ZIP as build-dist.ps1.
+#
+# Usage:
+#   ./build-dist-windows.sh [VERSION]
+#   ./build-dist-windows.sh v0.1.0-alpha.1
+#
+# Requirements: python3, pip, curl, unzip, zip, node/npm
+
+set -euo pipefail
+
+SCRIPT_DIR="$(cd "$(dirname "$0")" && pwd)"
+BUILD_DIR="$SCRIPT_DIR/build"
+DIST_NAME="LedGrab"
+DIST_DIR="$BUILD_DIR/$DIST_NAME"
+SERVER_DIR="$SCRIPT_DIR/server"
+PYTHON_DIR="$DIST_DIR/python"
+APP_DIR="$DIST_DIR/app"
+PYTHON_VERSION="${PYTHON_VERSION:-3.11.9}"
+
+# ── Version detection ────────────────────────────────────────
+
+VERSION="${1:-}"
+
+if [ -z "$VERSION" ]; then
+    VERSION=$(git describe --tags --exact-match 2>/dev/null || true)
+fi
+if [ -z "$VERSION" ]; then
+    VERSION="${GITEA_REF_NAME:-${GITHUB_REF_NAME:-}}"
+fi
+if [ -z "$VERSION" ]; then
+    VERSION=$(grep -oP '__version__\s*=\s*"\K[^"]+' "$SERVER_DIR/src/wled_controller/__init__.py" 2>/dev/null || echo "0.0.0")
+fi
+
+VERSION_CLEAN="${VERSION#v}"
+ZIP_NAME="LedGrab-v${VERSION_CLEAN}-win-x64.zip"
+
+echo "=== Cross-building LedGrab v${VERSION_CLEAN} (Windows from Linux) ==="
+echo "  Embedded Python: $PYTHON_VERSION"
+echo "  Output: build/$ZIP_NAME"
+echo ""
+
+# ── Clean ────────────────────────────────────────────────────
+
+if [ -d "$DIST_DIR" ]; then
+    echo "[1/8] Cleaning previous build..."
+    rm -rf "$DIST_DIR"
+fi
+mkdir -p "$DIST_DIR"
+
+# ── Download Windows embedded Python ─────────────────────────
+
+PYTHON_ZIP_URL="https://www.python.org/ftp/python/${PYTHON_VERSION}/python-${PYTHON_VERSION}-embed-amd64.zip"
+PYTHON_ZIP_PATH="$BUILD_DIR/python-embed-win.zip"
+
+echo "[2/8] Downloading Windows embedded Python ${PYTHON_VERSION}..."
+if [ ! -f "$PYTHON_ZIP_PATH" ]; then
+    curl -sL "$PYTHON_ZIP_URL" -o "$PYTHON_ZIP_PATH"
+fi
+mkdir -p "$PYTHON_DIR"
+unzip -qo "$PYTHON_ZIP_PATH" -d "$PYTHON_DIR"
+
+# ── Patch ._pth to enable site-packages ──────────────────────
+
+echo "[3/8] Patching Python path configuration..."
+PTH_FILE=$(ls "$PYTHON_DIR"/python*._pth 2>/dev/null | head -1)
+if [ -z "$PTH_FILE" ]; then
+    echo "ERROR: Could not find python*._pth in $PYTHON_DIR" >&2
+    exit 1
+fi
+
+# Uncomment 'import site' and add Lib\site-packages
+sed -i 's/^#\s*import site/import site/' "$PTH_FILE"
+if ! grep -q 'Lib\\site-packages' "$PTH_FILE"; then
+    echo 'Lib\site-packages' >> "$PTH_FILE"
+fi
+echo "  Patched $(basename "$PTH_FILE")"
+
+# ── Download pip and install into embedded Python ────────────
+
+echo "[4/8] Installing pip into embedded Python..."
+SITE_PACKAGES="$PYTHON_DIR/Lib/site-packages"
+mkdir -p "$SITE_PACKAGES"
+
+# Download pip + setuptools wheels for Windows
+pip download --quiet --dest "$BUILD_DIR/pip-wheels" \
+    --platform win_amd64 --python-version "3.11" \
+    --implementation cp --only-binary :all: \
+    pip setuptools 2>/dev/null || \
+pip download --quiet --dest "$BUILD_DIR/pip-wheels" \
+    pip setuptools
+
+# Unzip pip into site-packages (we just need it to exist, not to run)
+for whl in "$BUILD_DIR/pip-wheels"/pip-*.whl; do
+    unzip -qo "$whl" -d "$SITE_PACKAGES"
+done
+for whl in "$BUILD_DIR/pip-wheels"/setuptools-*.whl; do
+    unzip -qo "$whl" -d "$SITE_PACKAGES"
+done
+
+# ── Download Windows wheels for all dependencies ─────────────
+
+echo "[5/8] Downloading Windows dependencies..."
+WHEEL_DIR="$BUILD_DIR/win-wheels"
+mkdir -p "$WHEEL_DIR"
+
+# Core dependencies (cross-platform, should have win_amd64 wheels)
+# We parse pyproject.toml deps and download win_amd64 wheels.
+# For packages that are pure Python, --only-binary will fail,
+# so we fall back to allowing source for those.
+DEPS=(
+    "fastapi>=0.115.0"
+    "uvicorn[standard]>=0.32.0"
+    "httpx>=0.27.2"
+    "mss>=9.0.2"
+    "Pillow>=10.4.0"
+    "numpy>=2.1.3"
+    "pydantic>=2.9.2"
+    "pydantic-settings>=2.6.0"
+    "PyYAML>=6.0.2"
+    "structlog>=24.4.0"
+    "python-json-logger>=3.1.0"
+    "python-dateutil>=2.9.0"
+    "python-multipart>=0.0.12"
+    "jinja2>=3.1.0"
+    "zeroconf>=0.131.0"
+    "pyserial>=3.5"
+    "psutil>=5.9.0"
+    "nvidia-ml-py>=12.0.0"
+    "sounddevice>=0.5"
+    "aiomqtt>=2.0.0"
+    "openrgb-python>=0.2.15"
+    # camera extra
+    "opencv-python-headless>=4.8.0"
+)
+
+# Windows-only deps
+WIN_DEPS=(
+    "wmi>=1.5.1"
+    "PyAudioWPatch>=0.2.12"
+    "winsdk>=1.0.0b10"
+)
+
+# Download cross-platform deps (prefer binary, allow source for pure Python)
+for dep in "${DEPS[@]}"; do
+    pip download --quiet --dest "$WHEEL_DIR" \
+        --platform win_amd64 --python-version "3.11" \
+        --implementation cp --only-binary :all: \
+        "$dep" 2>/dev/null || \
+    pip download --quiet --dest "$WHEEL_DIR" \
+        --platform win_amd64 --python-version "3.11" \
+        --implementation cp \
+        "$dep" 2>/dev/null || \
+    pip download --quiet --dest "$WHEEL_DIR" "$dep" 2>/dev/null || \
+    echo "  WARNING: Could not download $dep (skipping)"
+done
+
+# Download Windows-only deps (best effort)
+for dep in "${WIN_DEPS[@]}"; do
+    pip download --quiet --dest "$WHEEL_DIR" \
+        --platform win_amd64 --python-version "3.11" \
+        --implementation cp --only-binary :all: \
+        "$dep" 2>/dev/null || \
+    pip download --quiet --dest "$WHEEL_DIR" \
+        --platform win_amd64 --python-version "3.11" \
+        --implementation cp \
+        "$dep" 2>/dev/null || \
+    echo "  WARNING: Could not download $dep (skipping, Windows-only)"
+done
+
+# Install all downloaded wheels into site-packages
+echo "  Installing $(ls "$WHEEL_DIR"/*.whl 2>/dev/null | wc -l) wheels into site-packages..."
+for whl in "$WHEEL_DIR"/*.whl; do
+    [ -f "$whl" ] && unzip -qo "$whl" -d "$SITE_PACKAGES" 2>/dev/null || true
+done
+
+# Also extract any .tar.gz source packages (pure Python only)
+for sdist in "$WHEEL_DIR"/*.tar.gz; do
+    [ -f "$sdist" ] || continue
+    TMPDIR=$(mktemp -d)
+    tar -xzf "$sdist" -C "$TMPDIR" 2>/dev/null || continue
+    # Find the package directory inside and copy it
+    PKG_DIR=$(find "$TMPDIR" -maxdepth 2 -name "*.py" -path "*/setup.py" -exec dirname {} \; | head -1)
+    if [ -n "$PKG_DIR" ] && [ -d "$PKG_DIR/src" ]; then
+        cp -r "$PKG_DIR/src/"* "$SITE_PACKAGES/" 2>/dev/null || true
+    elif [ -n "$PKG_DIR" ]; then
+        # Copy any Python package directories
+        find "$PKG_DIR" -maxdepth 1 -type d -name "[a-z]*" -exec cp -r {} "$SITE_PACKAGES/" \; 2>/dev/null || true
+    fi
+    rm -rf "$TMPDIR"
+done
+
+# Remove dist-info, caches, tests to reduce size
+find "$SITE_PACKAGES" -type d -name __pycache__ -exec rm -rf {} + 2>/dev/null || true
+find "$SITE_PACKAGES" -type d -name tests -exec rm -rf {} + 2>/dev/null || true
+find "$SITE_PACKAGES" -type d -name test -exec rm -rf {} + 2>/dev/null || true
+
+# Remove wled_controller if it got installed
+rm -rf "$SITE_PACKAGES"/wled_controller* "$SITE_PACKAGES"/wled*.dist-info 2>/dev/null || true
+
+WHEEL_COUNT=$(ls "$WHEEL_DIR"/*.whl 2>/dev/null | wc -l)
+echo "  Installed $WHEEL_COUNT packages"
+
+# ── Build frontend ───────────────────────────────────────────
+
+echo "[6/8] Building frontend bundle..."
+(cd "$SERVER_DIR" && npm ci --loglevel error && npm run build) 2>&1 | {
+    grep -v 'RemoteException' || true
+}
+
+# ── Copy application files ───────────────────────────────────
+
+echo "[7/8] Copying application files..."
+mkdir -p "$APP_DIR"
+
+cp -r "$SERVER_DIR/src" "$APP_DIR/src"
+cp -r "$SERVER_DIR/config" "$APP_DIR/config"
+mkdir -p "$DIST_DIR/data" "$DIST_DIR/logs"
+
+# Clean up source maps and __pycache__
+find "$APP_DIR" -name "*.map" -delete 2>/dev/null || true
+find "$APP_DIR" -type d -name __pycache__ -exec rm -rf {} + 2>/dev/null || true
+
+# ── Create launcher ──────────────────────────────────────────
+
+echo "[8/8] Creating launcher and packaging..."
+
+cat > "$DIST_DIR/LedGrab.bat" << LAUNCHER
+@echo off
+title LedGrab v${VERSION_CLEAN}
+cd /d "%~dp0"
+
+:: Set paths
+set PYTHONPATH=%~dp0app\src
+set WLED_CONFIG_PATH=%~dp0app\config\default_config.yaml
+
+:: Create data directory if missing
+if not exist "%~dp0data" mkdir "%~dp0data"
+if not exist "%~dp0logs" mkdir "%~dp0logs"
+
+echo.
+echo  =============================================
+echo   LedGrab v${VERSION_CLEAN}
+echo   Open http://localhost:8080 in your browser
+echo  =============================================
+echo.
+
+:: Start the server (open browser after short delay)
+start "" /b cmd /c "timeout /t 2 /nobreak >nul && start http://localhost:8080"
+"%~dp0python\python.exe" -m uvicorn wled_controller.main:app --host 0.0.0.0 --port 8080
+
+pause
+LAUNCHER
+
+# Convert launcher to Windows line endings
+sed -i 's/$/\r/' "$DIST_DIR/LedGrab.bat"
+
+# ── Create ZIP ───────────────────────────────────────────────
+
+ZIP_PATH="$BUILD_DIR/$ZIP_NAME"
+rm -f "$ZIP_PATH"
+
+(cd "$BUILD_DIR" && zip -rq "$ZIP_NAME" "$DIST_NAME")
+
+ZIP_SIZE=$(du -h "$ZIP_PATH" | cut -f1)
+echo ""
+echo "=== Build complete ==="
+echo "  Archive: $ZIP_PATH"
+echo "  Size: $ZIP_SIZE"
+echo ""

build-dist.sh

@@ -0,0 +1,133 @@
+#!/usr/bin/env bash
+#
+# Build a portable Linux distribution of LedGrab.
+# Produces a self-contained tarball with virtualenv and launcher script.
+#
+# Usage:
+#   ./build-dist.sh [VERSION]
+#   ./build-dist.sh v0.1.0-alpha.1
+
+set -euo pipefail
+
+SCRIPT_DIR="$(cd "$(dirname "$0")" && pwd)"
+BUILD_DIR="$SCRIPT_DIR/build"
+DIST_NAME="LedGrab"
+DIST_DIR="$BUILD_DIR/$DIST_NAME"
+SERVER_DIR="$SCRIPT_DIR/server"
+VENV_DIR="$DIST_DIR/venv"
+APP_DIR="$DIST_DIR/app"
+
+# ── Version detection ────────────────────────────────────────
+
+VERSION="${1:-}"
+
+if [ -z "$VERSION" ]; then
+    VERSION=$(git describe --tags --exact-match 2>/dev/null || true)
+fi
+if [ -z "$VERSION" ]; then
+    VERSION="${GITEA_REF_NAME:-${GITHUB_REF_NAME:-}}"
+fi
+if [ -z "$VERSION" ]; then
+    VERSION=$(grep -oP '__version__\s*=\s*"\K[^"]+' "$SERVER_DIR/src/wled_controller/__init__.py" 2>/dev/null || echo "0.0.0")
+fi
+
+VERSION_CLEAN="${VERSION#v}"
+TAR_NAME="LedGrab-v${VERSION_CLEAN}-linux-x64.tar.gz"
+
+echo "=== Building LedGrab v${VERSION_CLEAN} (Linux) ==="
+echo "  Output: build/$TAR_NAME"
+echo ""
+
+# ── Clean ────────────────────────────────────────────────────
+
+if [ -d "$DIST_DIR" ]; then
+    echo "[1/7] Cleaning previous build..."
+    rm -rf "$DIST_DIR"
+fi
+mkdir -p "$DIST_DIR"
+
+# ── Create virtualenv ────────────────────────────────────────
+
+echo "[2/7] Creating virtualenv..."
+python3 -m venv "$VENV_DIR"
+source "$VENV_DIR/bin/activate"
+pip install --upgrade pip --quiet
+
+# ── Install dependencies ─────────────────────────────────────
+
+echo "[3/7] Installing dependencies..."
+pip install --quiet "${SERVER_DIR}[camera,notifications]" 2>&1 | {
+    grep -i 'error\|failed' || true
+}
+
+# Remove the installed wled_controller package (PYTHONPATH handles app code)
+SITE_PACKAGES="$VENV_DIR/lib/python*/site-packages"
+rm -rf $SITE_PACKAGES/wled_controller* $SITE_PACKAGES/wled*.dist-info 2>/dev/null || true
+
+# Clean up caches
+find "$VENV_DIR" -type d -name __pycache__ -exec rm -rf {} + 2>/dev/null || true
+find "$VENV_DIR" -type d -name tests -exec rm -rf {} + 2>/dev/null || true
+find "$VENV_DIR" -type d -name test -exec rm -rf {} + 2>/dev/null || true
+
+# ── Build frontend ───────────────────────────────────────────
+
+echo "[4/7] Building frontend bundle..."
+(cd "$SERVER_DIR" && npm ci --loglevel error && npm run build) 2>&1 | {
+    grep -v 'RemoteException' || true
+}
+
+# ── Copy application files ───────────────────────────────────
+
+echo "[5/7] Copying application files..."
+mkdir -p "$APP_DIR"
+
+cp -r "$SERVER_DIR/src" "$APP_DIR/src"
+cp -r "$SERVER_DIR/config" "$APP_DIR/config"
+mkdir -p "$DIST_DIR/data" "$DIST_DIR/logs"
+
+# Clean up source maps and __pycache__
+find "$APP_DIR" -name "*.map" -delete 2>/dev/null || true
+find "$APP_DIR" -type d -name __pycache__ -exec rm -rf {} + 2>/dev/null || true
+
+# ── Create launcher ──────────────────────────────────────────
+
+echo "[6/7] Creating launcher..."
+cat > "$DIST_DIR/run.sh" << 'LAUNCHER'
+#!/usr/bin/env bash
+set -euo pipefail
+
+SCRIPT_DIR="$(cd "$(dirname "$0")" && pwd)"
+
+export PYTHONPATH="$SCRIPT_DIR/app/src"
+export WLED_CONFIG_PATH="$SCRIPT_DIR/app/config/default_config.yaml"
+
+mkdir -p "$SCRIPT_DIR/data" "$SCRIPT_DIR/logs"
+
+echo ""
+echo "  ============================================="
+echo "   LedGrab vVERSION_PLACEHOLDER"
+echo "   Open http://localhost:8080 in your browser"
+echo "  ============================================="
+echo ""
+
+source "$SCRIPT_DIR/venv/bin/activate"
+exec python -m uvicorn wled_controller.main:app --host 0.0.0.0 --port 8080
+LAUNCHER
+
+sed -i "s/VERSION_PLACEHOLDER/${VERSION_CLEAN}/" "$DIST_DIR/run.sh"
+chmod +x "$DIST_DIR/run.sh"
+
+# ── Create tarball ───────────────────────────────────────────
+
+echo "[7/7] Creating $TAR_NAME..."
+deactivate 2>/dev/null || true
+
+TAR_PATH="$BUILD_DIR/$TAR_NAME"
+(cd "$BUILD_DIR" && tar -czf "$TAR_NAME" "$DIST_NAME")
+
+TAR_SIZE=$(du -h "$TAR_PATH" | cut -f1)
+echo ""
+echo "=== Build complete ==="
+echo "  Archive: $TAR_PATH"
+echo "  Size: $TAR_SIZE"
+echo ""