Add S3 binary file support and resume download

- ensureLocalFile() downloads binary files (resume PDF) from S3 to temp
- Applier downloads resume from S3 before applying
- Cached in /tmp to avoid re-downloading each run

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

job_applier.mjs

@@ -20,6 +20,7 @@ process.stdout.write = (chunk, ...args) => { logStream.write(chunk); return orig
 process.stderr.write = (chunk, ...args) => { logStream.write(chunk); return origStderrWrite(chunk, ...args); };
 
 import { getJobsByStatus, updateJobStatus, appendLog, loadConfig, isAlreadyApplied, initQueue } from './lib/queue.mjs';
+import { ensureLocalFile } from './lib/storage.mjs';
 import { acquireLock } from './lib/lock.mjs';
 import { createBrowser } from './lib/browser.mjs';
 import { ensureAuth } from './lib/session.mjs';
@@ -45,6 +46,12 @@ async function main() {
   const settings = loadConfig(resolve(__dir, 'config/settings.json'));
   await initQueue(settings);
   const profile = loadConfig(resolve(__dir, 'config/profile.json'));
+
+  // Ensure resume is available locally (downloads from S3 if needed)
+  if (profile.resume_path) {
+    profile.resume_path = await ensureLocalFile('config/Matthew_Jackson_Resume.pdf', profile.resume_path);
+  }
+
   const answersPath = resolve(__dir, 'config/answers.json');
   const answers = existsSync(answersPath) ? loadConfig(answersPath) : [];
   const maxApps = settings.max_applications_per_run || Infinity;

lib/storage.mjs

@@ -2,7 +2,7 @@
  * storage.mjs — Pluggable data storage (local disk or S3)
  *
  * When type is "local": reads/writes go to local disk (default).
- * When type is "s3": S3 is the primary store. No local files for data.
+ * When type is "s3": S3 is the primary store.
  *   - Versioned bucket means every write is recoverable.
  *   - In-memory cache in queue.mjs handles read performance.
  *
@@ -10,8 +10,10 @@
  *   storage: { type: "s3", bucket: "claw-apply-data", region: "us-west-2" }
  *   storage: { type: "local" }  (default)
  */
-import { readFileSync, writeFileSync, existsSync } from 'fs';
-import { basename } from 'path';
+import { readFileSync, writeFileSync, existsSync, mkdirSync } from 'fs';
+import { basename, dirname } from 'path';
+import { tmpdir } from 'os';
+import { join } from 'path';
 
 let _s3Client = null;
 let _config = { type: 'local' };
@@ -101,8 +103,49 @@ export async function saveJSON(filePath, data) {
   }
 
   // Local storage — atomic write
+  const dir = dirname(filePath);
+  if (!existsSync(dir)) mkdirSync(dir, { recursive: true });
   const tmp = filePath + '.tmp';
   writeFileSync(tmp, body);
   const { renameSync } = await import('fs');
   renameSync(tmp, filePath);
 }
+
+/**
+ * Load a binary file (e.g. resume PDF) from storage.
+ * For S3: downloads to a temp file and returns the local path.
+ * For local: returns the path as-is (must already exist).
+ *
+ * @param {string} s3Key — S3 key (e.g. "config/Matthew_Jackson_Resume.pdf")
+ * @param {string} localPath — local file path (used as-is for local storage)
+ * @returns {string} — local file path (may be temp file for S3)
+ */
+export async function ensureLocalFile(s3Key, localPath) {
+  if (_config.type !== 's3') {
+    return localPath;
+  }
+
+  // If the file already exists locally (cached from previous download), use it
+  const tempPath = join(tmpdir(), basename(s3Key));
+  if (existsSync(tempPath)) return tempPath;
+
+  try {
+    const s3 = await getS3Client();
+    const response = await s3.client.send(new s3.GetObjectCommand({
+      Bucket: _config.bucket,
+      Key: s3Key,
+    }));
+    const chunks = [];
+    for await (const chunk of response.Body) {
+      chunks.push(chunk);
+    }
+    writeFileSync(tempPath, Buffer.concat(chunks));
+    console.log(`📄 Downloaded ${basename(s3Key)} from S3 (${chunks.reduce((s, c) => s + c.length, 0)} bytes)`);
+    return tempPath;
+  } catch (err) {
+    console.warn(`⚠️  Failed to download ${s3Key} from S3: ${err.message}`);
+    // Fall back to local path if it exists
+    if (existsSync(localPath)) return localPath;
+    throw new Error(`File not found: ${s3Key} (S3) or ${localPath} (local)`);
+  }
+}