From c8fd13120dca82261279456ea48f3ea0f50bd766 Mon Sep 17 00:00:00 2001
From: Neil <4138956+nwparker@users.noreply.github.com>
Date: Sat, 30 May 2026 12:47:27 -0700
Subject: [PATCH] fix: avoid project group order spread crash (#3675)

---
 src/main/persistence.test.ts | 30 ++++++++++++++++++++++++++++++
 src/main/persistence.ts      |  9 +++++----
 2 files changed, 35 insertions(+), 4 deletions(-)

diff --git a/src/main/persistence.test.ts b/src/main/persistence.test.ts
index 62ed05f03..9eb4236e4 100644
--- a/src/main/persistence.test.ts
+++ b/src/main/persistence.test.ts
@@ -16,6 +16,7 @@ import { join } from 'path'
 import { tmpdir } from 'os'
 import type {
   PersistedState,
+  ProjectGroup,
   Repo,
   TerminalPaneLayoutNode,
   TerminalTab,
@@ -1518,6 +1519,35 @@ describe('Store', () => {
     expect(store.getRepo('sibling')?.projectGroupId).toBe(sibling.id)
   })
 
+  it('creates a project group when persisted group history is very large', async () => {
+    const projectGroups: ProjectGroup[] = Array.from({ length: 130_000 }, (_, index) => ({
+      id: `group-${index}`,
+      name: `Group ${index}`,
+      parentPath: null,
+      parentGroupId: null,
+      createdFrom: 'manual',
+      tabOrder: index,
+      isCollapsed: false,
+      color: null,
+      createdAt: index,
+      updatedAt: index
+    }))
+    writeDataFile({
+      schemaVersion: 1,
+      repos: [],
+      worktreeMeta: {},
+      settings: {},
+      ui: {},
+      githubCache: { pr: {}, issue: {} },
+      projectGroups
+    })
+    const store = await createStore()
+
+    const group = store.createProjectGroup({ name: 'New group', createdFrom: 'manual' })
+
+    expect(group.tabOrder).toBe(projectGroups.length)
+  })
+
   it('sanitizes invalid project group updates before persisting a repo', async () => {
     const store = await createStore()
     const group = store.createProjectGroup({ name: 'Platform', createdFrom: 'manual' })
diff --git a/src/main/persistence.ts b/src/main/persistence.ts
index e3aef6063..2accd1887 100644
--- a/src/main/persistence.ts
+++ b/src/main/persistence.ts
@@ -2127,10 +2127,11 @@ export class Store {
     parentGroupId?: string | null
     createdFrom: ProjectGroup['createdFrom']
   }): ProjectGroup {
-    const maxOrder = Math.max(
-      -1,
-      ...(this.state.projectGroups ?? []).map((group) => group.tabOrder)
-    )
+    let maxOrder = -1
+    // Why: persisted group lists can be large enough to exceed spread limits.
+    for (const existingGroup of this.state.projectGroups ?? []) {
+      maxOrder = Math.max(maxOrder, existingGroup.tabOrder)
+    }
     const group = createProjectGroup({
       ...input,
       tabOrder: maxOrder + 1