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Start 1.142.2 + Bun leaks node:* modules in build for client #6169

@kylekz

Description

@kylekz

Which project does this relate to?

Start

Describe the bug

upgrading @tanstack/react-start to anything above 1.142.1 results in node:* modules leaking to the client and the build failing. title might not be accurate but it's all i could think of

bun + vite 8: https://gist.github.com/kylekz/3e85b56a25c37fef59b5445e23e7ceca
bun + vite 7.3: https://gist.github.com/kylekz/457b93257e7ef2c811cc725085996bb3
pnpm/node + vite 7.3: https://gist.github.com/kylekz/230b053d68911f8be81d8b25866d3953

i haven't been able to create a reproduction, but my actual repo is available: https://github.com/teamreflex/cosmo-web/tree/refactor/tanstack-start-vite-error
refactor/tanstack-start contains bun + vite 8.0.0-beta.3 + start 1.142.1 and is working
refactor/tanstack-start-vite-error contains bun + vite 7.3.0 + start 1.142.2 and is not working

the app uses bun runtime features so switching back to node isn't really an option. the app won't run with the env provided here but it'll get it past env validation in build. using bun 1.3.5.

Your Example Website or App

https://github.com/teamreflex/cosmo-web

Steps to Reproduce the Bug or Issue

git clone git@github.com:teamreflex/cosmo-web.git
cd cosmo-web
git checkout refactor/tanstack-start-vite-error
bun install
curl https://gist.githubusercontent.com/kylekz/a8afdc64513871b2791cd761c748e30c/raw/919bfacf8fd1532234f884f004651912d7031b1c/gistfile1.txt -o .env
turbo build --filter web

Expected behavior

build should succeed like 1.142.1 does

Screenshots or Videos

No response

Platform

  • Router / Start Version: 1.142.2
  • OS: Linux
  • Browser: Chrome
  • Browser Version: 143.0.7499.147
  • Bundler: vite
  • Bundler Version: 8.0.0-beta.3

Additional context

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