Here's how to reproduce the issue and the output of the failing test: $ cd /usr/tests/usr.bin/sed $ COLUMNS=80 kyua test ... multi_test:main -> failed: 1 of 130 tests failed [1.548s] ... $ kyua report ... *** /usr/tests/usr.bin/sed/regress.multitest.out/7.1 Sun Jul 31 16:04:49 2022 --- current.out Fri Dec 16 22:18:26 2022 *************** *** 1,15 **** \001\002\003\004\005\006\a\b\t$ ! \v\f\r\016\017\020\021\022\023\024\025\026\027\030\031\032\ ! \033\034\035\036\037 !"#$%&'()*+,-./0123456789:;<=>?@ABCDEF\ ! GHIJKLMNOPQRSTUVWXYZ[\]^_`abcdefghijklmnopqrstuvwxyz{|}~\ ! \177\200\201\202\203\204\205\206\207\210\211\212\213\214\ ! \215\216\217\220\221\222\223\224\225\226\227\230\231\232\ ! \233\234\235\236\237\240\241\242\243\244\245\246\247\250\ ! \251\252\253\254\255\256\257\260\261\262\263\264\265\266\ ! \267\270\271\272\273\274\275\276\277\300\301\302\303\304\ ! \305\306\307\310\311\312\313\314\315\316\317\320\321\322\ ! \323\324\325\326\327\330\331\332\333\334\335\336\337\340\ ! \341\342\343\344\345\346\347\350\351\352\353\354\355\356\ ! \357\360\361\362\363\364\365\366\367\370\371\372\373\374\ ! \375\376\377$ $ --- 1,11 ---- \001\002\003\004\005\006\a\b\t$ ! \v\f\r\016\017\020\021\022\023\024\025\026\027\030\031\032\033\034\035\036\037 \ ! !"#$%&'()*+,-./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_`abcdefghijklmno\ ! pqrstuvwxyz{|}~\177\200\201\202\203\204\205\206\207\210\211\212\213\214\215\216\ ! \217\220\221\222\223\224\225\226\227\230\231\232\233\234\235\236\237\240\241\ ! \242\243\244\245\246\247\250\251\252\253\254\255\256\257\260\261\262\263\264\ ! \265\266\267\270\271\272\273\274\275\276\277\300\301\302\303\304\305\306\307\ ! \310\311\312\313\314\315\316\317\320\321\322\323\324\325\326\327\330\331\332\ ! \333\334\335\336\337\340\341\342\343\344\345\346\347\350\351\352\353\354\355\ ! \356\357\360\361\362\363\364\365\366\367\370\371\372\373\374\375\376\377$ $ not ok 69 7.1 # Print and file routines A similar bug has been discovered recently in illumos: https://code.illumos.org/c/illumos-gate/+/2564 I've tested FreeBSD 14.0-CURRENT.
It seems to require a patch in the test suite so that we unset COLUMNS before proceeding with the tests. That would bring the consistency we need for the test suite. That's what the illumos developers are considering.
From the illumos man page for sed: ENVIRONMENT The COLUMNS,LANG,LC_ALL,LC_CTYPE and LC_COLLATE environment variables affect the execution of sed as described in environ(7). Our downstream of this test script sets LANG=C already, which was why I put `unset COLUMNS` in my proposed patch.