Fix/#638

server/index.ts

@@ -39,7 +39,6 @@ app.set('trust proxy', true)
 // ensure HTTPS only (X-Forwarded-Proto comes from Fly)
 app.use((req, res, next) => {
 	if (req.method !== 'GET') return next()
-
 	const proto = req.get('X-Forwarded-Proto')
 	const host = getHost(req)
 	if (proto === 'http') {
@@ -198,13 +197,19 @@ app.use((req, res, next) => {
 })
 
 async function getBuild() {
-	const build = viteDevServer
-		? viteDevServer.ssrLoadModule('virtual:remix/server-build')
-		: // @ts-ignore this should exist before running the server
-			// but it may not exist just yet.
-			await import('../build/server/index.js')
-	// not sure how to make this happy 🤷‍♂️
-	return build as unknown as ServerBuild
+	try {
+		const build = viteDevServer
+			? await viteDevServer.ssrLoadModule('virtual:remix/server-build')
+			: // @ts-expect-error - the file might not exist yet but it will
+				// eslint-disable-next-line import/no-unresolved
+				await import('../build/server/index.js')
+
+		return { build: build as unknown as ServerBuild, error: null }
+	} catch (error) {
+		// Catch error and return null to make express happy and avoid an unrecoverable crash
+		console.error('Error creating build:', error)
+		return { error: error, build: null as unknown as ServerBuild }
+	}
 }
 
 if (!ALLOW_INDEXING) {
@@ -222,7 +227,14 @@ app.all(
 			serverBuild: getBuild(),
 		}),
 		mode: MODE,
-		build: getBuild,
+		build: async () => {
+			const { error, build } = await getBuild()
+			// gracefully "catch" the error
+			if (error) {
+				throw error
+			}
+			return build
+		},
 	}),
 )