fix(docs): make search work on the static site (client-side flexsearch)

The search dialog used `type: 'hanzo'`, POSTing to a remote auth-gated API a
public static site can't call — every query silently returned empty. The
`/api/search` route also froze to the force-static empty-query `[]`.

- route: export `staticGET` (the whole flexsearch index) instead of the dynamic
  GET; tokenize `forward` (prefix / as-you-type) over titles + section headings
  only. A full-body forward index exceeds V8's max string length and OOMs the
  export; headings-only is ~20MB / 1.7MB gzipped.
- dialog: `type: 'flexsearch-static'` from /api/search — no server, no auth.
- core: wire the missing `flexsearch-static` case into useDocsSearch; re-export
  buildIndexDefault so the route can tag pages (All/Services/SDKs/API/Products).

Verified on the built out/api/search: agents 85, authentication 113, getting
started 40, prefix "deplo"->/docs/deploy; all five filters return results.

apps/docs/app/api/search/route.ts

@@ -1,7 +1,64 @@
 import { source } from '@/lib/source';
-import { flexsearchFromSource } from '@hanzo/docs-core/search/flexsearch';
+import { buildIndexDefault, flexsearchFromSource } from '@hanzo/docs-core/search/flexsearch';
+import { getSection } from '@/lib/source/navigation';
 
-export const { GET } = flexsearchFromSource(source);
+// The search dialog's "Products" filter covers Zen LM, Chat, MCP, Dev and ZAP.
+// getSection keeps those as distinct sections, so we additionally tag their
+// pages `products` for that one filter. The other filters (Services/SDKs/API)
+// match the single section tag as before — flexsearch tags are a set, so a
+// page can carry both its section and `products`.
+const PRODUCT_SECTIONS = new Set(['chat', 'llm', 'mcp', 'dev', 'zap']);
 
-// Static flexsearch index for CF Pages static export.
-export const dynamic = 'force-static';
+function sectionTags(slug: string | undefined): string | string[] {
+  const section = getSection(slug);
+  return PRODUCT_SECTIONS.has(section) ? [section, 'products'] : section;
+}
+
+// Client-side static search for the static export (served by hanzoai/static).
+//
+// `staticGET` serializes the flexsearch index to /api/search; the browser
+// (search dialog, `type: 'flexsearch-static'`) downloads it once and searches
+// locally — no server, no auth, works on a static host. This replaces the old
+// `GET` (dynamic search handler) which, under `dynamic = 'force-static'`, froze
+// to the empty-query response `[]`, so every search returned nothing.
+//
+// Index shape is tuned for this corpus (~1.7k docs):
+//   - `tokenize: 'forward'` gives prefix / search-as-you-type matching.
+//   - We index titles, descriptions and section headings, NOT body paragraphs
+//     (`contents: []`). Indexing full bodies with a prefix tokenizer produces a
+//     serialized index that exceeds V8's max string length and OOMs the build;
+//     headings-only keeps it at ~20MB (~1.7MB gzipped) while still matching the
+//     titles/headings users actually search for. Deep body text is reachable
+//     via the on-page anchors those headings link to.
+//
+// Tags mirror /static.json (getSection over the top-level slug) so the
+// All/Services/SDKs/API filters narrow correctly.
+export const { staticGET: GET } = flexsearchFromSource(source, {
+  document: { tokenize: 'forward' },
+  async buildIndex(page) {
+    const tag = sectionTags(page.slugs[0]);
+
+    // OpenAPI pages carry no MDX structured data; index title/description only.
+    // (In static-export mode they aren't generated at all, so this is a no-op
+    // there — it keeps `next dev`, where specs are present, from throwing.)
+    if (page.type === 'openapi') {
+      return {
+        id: page.url,
+        url: page.url,
+        title: page.data.title ?? page.url,
+        description: page.data.description,
+        tag,
+        structuredData: { headings: [], contents: [] },
+      };
+    }
+
+    const base = await buildIndexDefault(page);
+    return {
+      ...base,
+      tag,
+      structuredData: { headings: base.structuredData.headings, contents: [] },
+    };
+  },
+});
+
+export const revalidate = false;

apps/docs/components/layouts/search.tsx

@@ -22,7 +22,6 @@ import { cn } from '@/lib/cn';
 import { useTreeContext } from '@hanzo/docs/ui/contexts/tree';
 import type { Item, Node } from '@hanzo/docs/core/page-tree';
 import { useRouter } from 'next/navigation';
-import { publishableKey, searchEndpoint, searchBackend, searchIndex } from '@/lib/hanzo/client';
 
 const items = [
   {
@@ -55,11 +54,8 @@ export default function CustomSearchDialog(props: SharedProps) {
   const [open, setOpen] = useState(false);
   const [tag, setTag] = useState<string | undefined>();
   const { search, setSearch, query } = useDocsSearch({
-    type: 'hanzo',
-    apiKey: publishableKey,
-    endpoint: searchEndpoint,
-    backend: searchBackend,
-    index: searchIndex,
+    type: 'flexsearch-static',
+    from: '/api/search',
     tag,
   });
   const { full } = useTreeContext();

packages/core/src/search/client.ts

@@ -147,6 +147,15 @@ export function useDocsSearch(
         client = oramaStaticClient(clientRest);
         break;
       }
+      case 'flexsearch-static': {
+        const res = (promiseMap[clientRest.type] ??=
+          import('./client/flexsearch-static')) as Promise<
+          typeof import('./client/flexsearch-static')
+        >;
+        const { flexsearchStaticClient } = use(res);
+        client = flexsearchStaticClient(clientRest);
+        break;
+      }
       case 'hanzo': {
         const res = (promiseMap[clientRest.type] ??= import('./client/hanzo')) as Promise<
           typeof import('./client/hanzo')

packages/core/src/search/flexsearch.ts

@@ -8,6 +8,10 @@ import type { Awaitable } from '@/types';
 import type { I18nConfig } from '@/i18n';
 import { createDocument, search, type Doc } from './flexsearch/utils';
 
+// Re-exported so apps can wrap the default page->index builder (e.g. to attach
+// a `tag` for filtered client-side search) instead of reimplementing it.
+export { buildIndexDefault } from './server/build-index';
+
 export type Index = SharedIndex;
 export interface IndexWithLocale extends Index {
   locale: string;