Error: Unable to unpack repo: there was at least one filename that was too long

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Current: Deployments fail with error “Unable to unpack repo: there was at least one filename that was too long” (GIT_REPO_FILENAME_TOO_LONG).
Expected: Deployments should complete successfully since my local Git audit shows no files with long paths.

  1. Push any commit to main or any branch
  2. Deployment fails immediately with the filename too long error
    Troubleshooting already done:

  • Local Git tree audit results:

    • max full path: 54 bytes
    • max filename/component: 40 bytes
    • no suspicious paths
    • no case-insensitive collisions

  • Attempted redeploy WITH Clear Build Cache - failed

  • Attempted redeploy WITHOUT Clear Build Cache - failed

  • Error persists across multiple branches (main and feature branches)
    This suggests the issue is not with versioned files but possibly a corrupted cache/snapshot on Vercel’s side.

  • - Project name: tho-web

    - Framework: Next.js

    - Node version: 24.x

    - Repository: THO-Jer/tho-web

    - Production branch: main

    - Error appears on: multiple branches including main

    - Plan: Hobby

I cannot create a new Vercel project as a workaround because I have an active redirect pointing to the production deployment of this project - this is the main website for my work/business.