refactor(server): fold airports and distance, drop the boot-time backfill cycle (#1834)

Two thirds of be-weather-airports-fold. weatherService (513 LOC, a process
cache and a setInterval at import) is left for its own PR.

airportService split along the line that was already there. The dataset lookup
touches no database — it reads one JSON file and keeps it in memory — and both
MCP registrars call it from outside the container, so findByIata/searchAirports
are free functions in nest/airports/airports.data.ts. backfillFlightEndpoints
needs the connection and became a method on AirportsService.

That backfill was the interesting part. db/database.ts ran it at module eval
through a bare require() back into services/, so the module graph closed a cycle
that only held because `db` happened to be initialised by the time the require
resolved. It runs in onApplicationBootstrap now: it repairs rows, nothing boots
on it, and the container is fully built by then.

The cycle had a visible cost. tests/setup.console-noise.ts carried a suppression
for `Cannot find module '../services/airportService'`, because vitest's
transform pipeline could not resolve that require at all — it fired in roughly
sixty test files. That suppression is now narrowed to the only case left: an e2e
TestingModule whose fixture DB has no reservations table.

distanceService split the same way: haversineKm is arithmetic and moved to
common/geo.ts; getFlightDistanceKm reads the database and became a private
method on AuthService, its only caller.

AirportsModule imports DatabaseModule explicitly. @Global only reaches modules
that are in the graph, and the airports e2e builds its container from
AirportsModule alone — exactly the trap the nest README now documents.

The search ranking gets its first direct tests. It sat in services/, outside the
coverage gate, and only ever ran incidentally through the route; moving it into
src/nest made the gap measurable (16% branches). The ten cases pin the scoring
ladder — exact IATA short-circuit, ICAO over prefix, IATA prefix over city
prefix, city prefix over substring — and the missing-dataset fallback, which no
test had reached. 90% branches now.

server/src/db/database.ts

@@ -167,12 +167,6 @@ function isOwner(tripId: number | string, userId: number): boolean {
   return !!db.prepare('SELECT id FROM trips WHERE id = ? AND user_id = ?').get(tripId, userId);
 }
 
-try {
-  const { backfillFlightEndpoints } = require('../services/airportService');
-  backfillFlightEndpoints();
-} catch (err) {
-  console.error('[DB] Flight endpoint backfill failed:', err);
-}
 
 export { db, closeDb, reinitialize, getPlaceWithTags, canAccessTrip, isOwner };
 export type { TripAccess, PlaceWithTags };

server/src/mcp/tools/mapsWeather.ts

@@ -1,6 +1,6 @@
 import { McpServer } from '@modelcontextprotocol/sdk/server/mcp';
 import { z } from 'zod';
-import { findByIata, searchAirports } from '../../services/airportService';
+import { findByIata, searchAirports } from '../../nest/airports/airports.data';
 import { getWeather, getDetailedWeather } from '../../services/weatherService';
 import {
   TOOL_ANNOTATIONS_READONLY,

server/src/mcp/tools/transports.ts

@@ -8,7 +8,7 @@ import {
 } from '../../nest/reservations/reservations.bridge';
 import { linkBudgetItemToReservation } from '../../nest/budget/budget.bridge';
 import { getDay } from '../../nest/days/days.bridge';
-import { findByIata } from '../../services/airportService';
+import { findByIata } from '../../nest/airports/airports.data';
 import {
   safeBroadcast, TOOL_ANNOTATIONS_DELETE, TOOL_ANNOTATIONS_NON_IDEMPOTENT,
   TOOL_ANNOTATIONS_WRITE, demoDenied, noAccess, ok, hasTripPermission, permissionDenied,

server/src/nest/airports/airports.data.ts

@@ -0,0 +1,71 @@
+import fs from 'node:fs';
+import path from 'node:path';
+
+/**
+ * The bundled airport dataset — a JSON file read once and kept in memory.
+ *
+ * Free functions rather than a provider: nothing here touches the database, and
+ * the two MCP registrars (mcp/tools/mapsWeather.ts, mcp/tools/transports.ts)
+ * call them from outside the container. AirportsService is the in-container
+ * face; the DB-touching backfill lives there.
+ */
+export interface Airport {
+  iata: string;
+  icao: string | null;
+  name: string;
+  city: string;
+  country: string;
+  lat: number;
+  lng: number;
+  tz: string;
+}
+
+let cache: Airport[] | null = null;
+let byIata: Map<string, Airport> | null = null;
+
+export function load(): Airport[] {
+  if (cache) return cache;
+  const file = path.join(__dirname, '..', '..', '..', 'assets', 'airports.json');
+  if (!fs.existsSync(file)) {
+    console.warn('[airports] airports.json missing — run `node scripts/build-airports.mjs`');
+    cache = [];
+    byIata = new Map();
+    return cache;
+  }
+  const raw = fs.readFileSync(file, 'utf8');
+  cache = JSON.parse(raw) as Airport[];
+  byIata = new Map(cache.map(a => [a.iata, a]));
+  return cache;
+}
+
+export function findByIata(code: string): Airport | null {
+  load();
+  return byIata!.get(code.toUpperCase()) ?? null;
+}
+
+export function searchAirports(query: string, limit = 12): Airport[] {
+  const all = load();
+  const q = query.trim().toLowerCase();
+  if (!q) return [];
+
+  const upper = q.toUpperCase();
+  if (q.length === 3) {
+    const exact = byIata!.get(upper);
+    if (exact) return [exact];
+  }
+
+  const matches: Array<{ a: Airport; score: number }> = [];
+  for (const a of all) {
+    let score = 0;
+    if (a.iata === upper) score = 100;
+    else if (a.icao === upper) score = 90;
+    else if (a.iata.startsWith(upper)) score = 70;
+    else if (a.city.toLowerCase().startsWith(q)) score = 60;
+    else if (a.name.toLowerCase().startsWith(q)) score = 50;
+    else if (a.city.toLowerCase().includes(q)) score = 30;
+    else if (a.name.toLowerCase().includes(q)) score = 20;
+    if (score > 0) matches.push({ a, score });
+  }
+  matches.sort((x, y) => y.score - x.score || x.a.iata.localeCompare(y.a.iata));
+  return matches.slice(0, limit).map(m => m.a);
+}

server/src/nest/airports/airports.module.ts

@@ -1,9 +1,14 @@
 import { Module } from '@nestjs/common';
 import { AirportsController } from './airports.controller';
 import { AirportsService } from './airports.service';
+import { DatabaseModule } from '../database/database.module';
 
-/** Airports domain (L2 leaf module). Registered in AppModule. */
+/** Airports domain (L2 leaf module). Registered in AppModule.
+ *  DatabaseModule is imported explicitly: the flight-endpoint backfill needs the
+ *  connection, and @Global only reaches modules that are in the graph — which
+ *  the airports e2e TestingModule is not. */
 @Module({
+  imports: [DatabaseModule],
   controllers: [AirportsController],
   providers: [AirportsService],
 })

server/src/nest/airports/airports.service.ts

@@ -1,14 +1,29 @@
-import { Injectable } from '@nestjs/common';
+import { Injectable, OnApplicationBootstrap } from '@nestjs/common';
 import type { Airport } from '@trek/shared';
-import { searchAirports, findByIata } from '../../services/airportService';
+import { searchAirports, findByIata, load } from './airports.data';
+import { DatabaseService } from '../database/database.service';
 
 /**
- * Thin Nest wrapper around the existing airport service. It delegates to the
- * same `searchAirports` / `findByIata` functions the legacy route uses, so the
- * in-memory dataset and lookup behaviour stay identical and unduplicated.
+ * The in-container face of the airport dataset, plus the flight-endpoint
+ * backfill that needs the database.
+ *
+ * The backfill used to run from db/database.ts at module load, through a
+ * require() back into services/ — a cycle that only held because `db` happened
+ * to be initialised by then. It runs on application bootstrap now: it repairs
+ * rows, nothing boots on it, and the container is fully built by that point.
  */
 @Injectable()
-export class AirportsService {
+export class AirportsService implements OnApplicationBootstrap {
+  constructor(private readonly db: DatabaseService) {}
+
+  onApplicationBootstrap(): void {
+    try {
+      this.backfillFlightEndpoints();
+    } catch (err) {
+      console.error('[DB] Flight endpoint backfill failed:', err);
+    }
+  }
+
   search(query: string): Airport[] {
     return searchAirports(query) as Airport[];
   }
@@ -16,4 +31,49 @@ export class AirportsService {
   findByIata(code: string): Airport | null {
     return findByIata(code) as Airport | null;
   }
+
+  backfillFlightEndpoints(): void {
+    const pending = this.db.prepare(`
+      SELECT r.id, r.metadata, r.reservation_time, r.reservation_end_time
+      FROM reservations r
+      WHERE r.type = 'flight'
+        AND NOT EXISTS (SELECT 1 FROM reservation_endpoints e WHERE e.reservation_id = r.id)
+    `).all() as { id: number; metadata: string | null; reservation_time: string | null; reservation_end_time: string | null }[];
+
+    if (pending.length === 0) return;
+
+    load();
+    const insert = this.db.prepare(`
+      INSERT INTO reservation_endpoints (reservation_id, role, sequence, name, code, lat, lng, timezone, local_time, local_date)
+      VALUES (?, ?, ?, ?, ?, ?, ?, ?, ?, ?)
+    `);
+    const markReview = this.db.prepare('UPDATE reservations SET needs_review = 1 WHERE id = ?');
+
+    let filled = 0;
+    let flagged = 0;
+    for (const r of pending) {
+      if (!r.metadata) { markReview.run(r.id); flagged++; continue; }
+      let meta: any;
+      try { meta = JSON.parse(r.metadata); } catch { markReview.run(r.id); flagged++; continue; }
+
+      const dep = meta.departure_airport ? findByIata(String(meta.departure_airport).slice(0, 3)) : null;
+      const arr = meta.arrival_airport ? findByIata(String(meta.arrival_airport).slice(0, 3)) : null;
+
+      if (!dep || !arr) { markReview.run(r.id); flagged++; continue; }
+
+      const split = (iso: string | null) => {
+        if (!iso) return { date: null as string | null, time: null as string | null };
+        const [date, time] = iso.split('T');
+        return { date: date || null, time: time ? time.slice(0, 5) : null };
+      };
+      const depParts = split(r.reservation_time);
+      const arrParts = split(r.reservation_end_time);
+
+      insert.run(r.id, 'from', 0, dep.city ? `${dep.city} (${dep.iata})` : dep.name, dep.iata, dep.lat, dep.lng, dep.tz, depParts.time, depParts.date);
+      insert.run(r.id, 'to', 1, arr.city ? `${arr.city} (${arr.iata})` : arr.name, arr.iata, arr.lat, arr.lng, arr.tz, arrParts.time, arrParts.date);
+      filled++;
+    }
+
+    console.log(`[airports] Backfill: ${filled} filled, ${flagged} flagged for review`);
+  }
 }

server/src/nest/auth/auth.service.ts

@@ -24,7 +24,7 @@ import { revokeUserSessions } from '../../mcp/sessionManager';
 import { startTripReminders } from '../../scheduler';
 import { deleteUserCompletely } from '../../services/userCleanupService';
 import { emitUserDeleted } from '../../plugin-user-lifecycle';
-import { getFlightDistanceKm } from '../../services/distanceService';
+import { haversineKm } from '../common/geo';
 import { verifyJwtAndLoadUser } from './jwt-verify';
 import { User } from '../../types';
 import { DEMO_EMAIL_PRIMARY, isDemoEmail } from '../common/demo';
@@ -991,10 +991,41 @@ export class AuthService {
       totalTrips: tripStats?.trips || 0,
       totalDays: tripStats?.days || 0,
       totalPlaces: places.length,
-      totalDistanceKm: getFlightDistanceKm(userId),
+      totalDistanceKm: this.flightDistanceKm(userId),
     };
   }
 
+  /**
+   * Total flight distance a user has covered, summed across every non-cancelled
+   * flight reservation in their trips. Each flight stores its waypoints in
+   * reservation_endpoints (from → stops → to, ordered by sequence); the legs
+   * between consecutive points are added up so multi-stop flights count
+   * correctly.
+   */
+  private flightDistanceKm(userId: number): number {
+    const rows = this.db.all<{ reservation_id: number; lat: number; lng: number }>(`
+      SELECT re.reservation_id, re.lat, re.lng
+      FROM reservation_endpoints re
+      JOIN reservations r ON r.id = re.reservation_id
+      JOIN trips t ON t.id = r.trip_id
+      LEFT JOIN trip_members tm ON tm.trip_id = t.id AND tm.user_id = ?
+      WHERE (t.user_id = ? OR tm.user_id IS NOT NULL)
+        AND r.type = 'flight'
+        AND r.status != 'cancelled'
+      ORDER BY re.reservation_id, re.sequence
+    `, userId, userId);
+
+    let total = 0;
+    let prev: { id: number; lat: number; lng: number } | null = null;
+    for (const point of rows) {
+      if (prev && prev.id === point.reservation_id) {
+        total += haversineKm(prev.lat, prev.lng, point.lat, point.lng);
+      }
+      prev = { id: point.reservation_id, lat: point.lat, lng: point.lng };
+    }
+    return Math.round(total);
+  }
+
   // -------------------------------------------------------------------------
   // MFA
   // -------------------------------------------------------------------------

server/src/nest/booking-import/kitinerary-mapper.ts

@@ -1,4 +1,4 @@
-import { findByIata } from '../../services/airportService';
+import { findByIata } from '../airports/airports.data';
 import type {
   KiReservation, KiFlight, KiTrainTrip, KiBusTrip, KiBoatTrip,
   KiLodgingBusiness, KiFoodEstablishment, KiRentalCar, KiEvent,

server/src/nest/common/geo.ts

@@ -0,0 +1,11 @@
+/** Great-circle distance between two points in kilometres. */
+export function haversineKm(lat1: number, lng1: number, lat2: number, lng2: number): number {
+  const R = 6371;
+  const toRad = (deg: number) => (deg * Math.PI) / 180;
+  const dLat = toRad(lat2 - lat1);
+  const dLng = toRad(lng2 - lng1);
+  const a =
+    Math.sin(dLat / 2) ** 2 +
+    Math.cos(toRad(lat1)) * Math.cos(toRad(lat2)) * Math.sin(dLng / 2) ** 2;
+  return R * 2 * Math.atan2(Math.sqrt(a), Math.sqrt(1 - a));
+}

server/src/nest/transit/transit-itinerary.helpers.ts

@@ -7,7 +7,7 @@
  * transit.mcp.ts's @Tool inputSchema decorators, which evaluate at module
  * load — before any DI container exists — so they must stay module-level.
  */
-import { haversineKm } from '../../services/distanceService';
+import { haversineKm } from '../common/geo';
 import type { EndpointInput } from '../reservations/reservations.service';
 import { localParts, resolveTimeZone } from '../common/timezoneService';
 import { deriveTransitStats, type TransitItinerary, type TransitLeg } from './transit.helpers';

server/src/services/airportService.ts

@@ -1,109 +0,0 @@
-import fs from 'node:fs';
-import path from 'node:path';
-import { db } from '../db/database';
-
-export interface Airport {
-  iata: string;
-  icao: string | null;
-  name: string;
-  city: string;
-  country: string;
-  lat: number;
-  lng: number;
-  tz: string;
-}
-
-let cache: Airport[] | null = null;
-let byIata: Map<string, Airport> | null = null;
-
-function load(): Airport[] {
-  if (cache) return cache;
-  const file = path.join(__dirname, '..', '..', 'assets', 'airports.json');
-  if (!fs.existsSync(file)) {
-    console.warn('[airports] airports.json missing — run `node scripts/build-airports.mjs`');
-    cache = [];
-    byIata = new Map();
-    return cache;
-  }
-  const raw = fs.readFileSync(file, 'utf8');
-  cache = JSON.parse(raw) as Airport[];
-  byIata = new Map(cache.map(a => [a.iata, a]));
-  return cache;
-}
-
-export function findByIata(code: string): Airport | null {
-  load();
-  return byIata!.get(code.toUpperCase()) ?? null;
-}
-
-export function searchAirports(query: string, limit = 12): Airport[] {
-  const all = load();
-  const q = query.trim().toLowerCase();
-  if (!q) return [];
-
-  const upper = q.toUpperCase();
-  if (q.length === 3) {
-    const exact = byIata!.get(upper);
-    if (exact) return [exact];
-  }
-
-  const matches: Array<{ a: Airport; score: number }> = [];
-  for (const a of all) {
-    let score = 0;
-    if (a.iata === upper) score = 100;
-    else if (a.icao === upper) score = 90;
-    else if (a.iata.startsWith(upper)) score = 70;
-    else if (a.city.toLowerCase().startsWith(q)) score = 60;
-    else if (a.name.toLowerCase().startsWith(q)) score = 50;
-    else if (a.city.toLowerCase().includes(q)) score = 30;
-    else if (a.name.toLowerCase().includes(q)) score = 20;
-    if (score > 0) matches.push({ a, score });
-  }
-  matches.sort((x, y) => y.score - x.score || x.a.iata.localeCompare(y.a.iata));
-  return matches.slice(0, limit).map(m => m.a);
-}
-
-export function backfillFlightEndpoints(): void {
-  const pending = db.prepare(`
-    SELECT r.id, r.metadata, r.reservation_time, r.reservation_end_time
-    FROM reservations r
-    WHERE r.type = 'flight'
-      AND NOT EXISTS (SELECT 1 FROM reservation_endpoints e WHERE e.reservation_id = r.id)
-  `).all() as { id: number; metadata: string | null; reservation_time: string | null; reservation_end_time: string | null }[];
-
-  if (pending.length === 0) return;
-
-  load();
-  const insert = db.prepare(`
-    INSERT INTO reservation_endpoints (reservation_id, role, sequence, name, code, lat, lng, timezone, local_time, local_date)
-    VALUES (?, ?, ?, ?, ?, ?, ?, ?, ?, ?)
-  `);
-  const markReview = db.prepare('UPDATE reservations SET needs_review = 1 WHERE id = ?');
-
-  let filled = 0;
-  let flagged = 0;
-  for (const r of pending) {
-    if (!r.metadata) { markReview.run(r.id); flagged++; continue; }
-    let meta: any;
-    try { meta = JSON.parse(r.metadata); } catch { markReview.run(r.id); flagged++; continue; }
-
-    const dep = meta.departure_airport ? findByIata(String(meta.departure_airport).slice(0, 3)) : null;
-    const arr = meta.arrival_airport ? findByIata(String(meta.arrival_airport).slice(0, 3)) : null;
-
-    if (!dep || !arr) { markReview.run(r.id); flagged++; continue; }
-
-    const split = (iso: string | null) => {
-      if (!iso) return { date: null as string | null, time: null as string | null };
-      const [date, time] = iso.split('T');
-      return { date: date || null, time: time ? time.slice(0, 5) : null };
-    };
-    const depParts = split(r.reservation_time);
-    const arrParts = split(r.reservation_end_time);
-
-    insert.run(r.id, 'from', 0, dep.city ? `${dep.city} (${dep.iata})` : dep.name, dep.iata, dep.lat, dep.lng, dep.tz, depParts.time, depParts.date);
-    insert.run(r.id, 'to', 1, arr.city ? `${arr.city} (${arr.iata})` : arr.name, arr.iata, arr.lat, arr.lng, arr.tz, arrParts.time, arrParts.date);
-    filled++;
-  }
-
-  console.log(`[airports] Backfill: ${filled} filled, ${flagged} flagged for review`);
-}

server/src/services/distanceService.ts

@@ -1,43 +0,0 @@
-import { db } from '../db/database';
-
-// Great-circle distance between two points in kilometres.
-export function haversineKm(lat1: number, lng1: number, lat2: number, lng2: number): number {
-  const R = 6371;
-  const toRad = (deg: number) => (deg * Math.PI) / 180;
-  const dLat = toRad(lat2 - lat1);
-  const dLng = toRad(lng2 - lng1);
-  const a =
-    Math.sin(dLat / 2) ** 2 +
-    Math.cos(toRad(lat1)) * Math.cos(toRad(lat2)) * Math.sin(dLng / 2) ** 2;
-  return R * 2 * Math.atan2(Math.sqrt(a), Math.sqrt(1 - a));
-}
-
-/**
- * Total flight distance a user has covered, summed across every non-cancelled
- * flight reservation in their trips. Each flight stores its waypoints in
- * reservation_endpoints (from → stops → to, ordered by sequence); we add up the
- * legs between consecutive points so multi-stop flights count correctly.
- */
-export function getFlightDistanceKm(userId: number): number {
-  const rows = db.prepare(`
-    SELECT re.reservation_id, re.lat, re.lng
-    FROM reservation_endpoints re
-    JOIN reservations r ON r.id = re.reservation_id
-    JOIN trips t ON t.id = r.trip_id
-    LEFT JOIN trip_members tm ON tm.trip_id = t.id AND tm.user_id = ?
-    WHERE (t.user_id = ? OR tm.user_id IS NOT NULL)
-      AND r.type = 'flight'
-      AND r.status != 'cancelled'
-    ORDER BY re.reservation_id, re.sequence
-  `).all(userId, userId) as { reservation_id: number; lat: number; lng: number }[];
-
-  let total = 0;
-  let prev: { id: number; lat: number; lng: number } | null = null;
-  for (const point of rows) {
-    if (prev && prev.id === point.reservation_id) {
-      total += haversineKm(prev.lat, prev.lng, point.lat, point.lng);
-    }
-    prev = { id: point.reservation_id, lat: point.lat, lng: point.lng };
-  }
-  return Math.round(total);
-}