feat(backup): prod's off-cluster DR lands on R2 — and stops the WAL clock
Prod has been archiving WAL to `TBD-PROD-S3-BACKUP-ENDPOINT` since bootstrap. Verified live 2026-09-07 on all three CNPG Clusters: ContinuousArchiving=False, "unexpected failure invoking barman-cloud-wal-archive: exit status 4". Because archive_mode is ON, that is not a degraded backup — it is a DISK-FULL CLOCK. Postgres will not recycle a segment it has not archived, so keycloak-db's pgdata PVC is at 579 MiB used / 4360 MiB free and climbing monotonically. When it fills, the primary PANICs and takes SSO down, and with it kubectl OIDC, Grafana, Headlamp, Gitea and forward-auth. Wiring the endpoint is what lets Postgres drain the whole accumulated backlog in one pass. THE KNOB LAYOUT (three new, one repurposed) and why it is shaped this way. The operator created exactly ONE R2 bucket, `k3s-prod-backup`, but the two backup tools want differently-SHAPED values: the Velero chart takes `bucket` and `prefix` as separate fields, while CNPG's barmanObjectStore.destinationPath is one full s3:// URL whose first path segment IS the bucket. So: S3_BACKUP_ENDPOINT dev http://192.168.1.9:9000 prod https://<acct>.r2... S3_BACKUP_REGION dev us-east-1 prod auto VELERO_BACKUP_BUCKET dev velero prod k3s-prod-backup VELERO_BACKUP_PREFIX dev "" prod velero CNPG_BACKUP_PATH dev s3://cnpg prod s3://k3s-prod-backup/barman There is deliberately NO separate `S3_BACKUP_BUCKET`: CNPG's bucket already lives inside CNPG_BACKUP_PATH, and a second knob holding the same bucket name twice is a rotation waiting to drift. Three knobs, each shaped for its own consumer, and no two of them can contradict each other. TENANCY. Inside k3s-prod-backup, velero and barman get disjoint TOP-LEVEL prefixes — s3://k3s-prod-backup/velero/ and s3://k3s-prod-backup/barman/<cluster>/ — with the bucket ROOT left empty so a misrendered prefix lands somewhere obviously wrong instead of silently colliding. This is not tidiness: Velero ADOPTS every backup under its location and TTL-DELETES it on retention, so an overlapping prefix would let it reap WAL segments; and interleaving two Postgres servers' WAL into one prefix corrupts the chain outright. Dev↔prod isolation is doubly independent — different endpoint AND different bucket names — so neither cluster can reach the other's objects even with a mis-substituted prefix. DEV IS UNCHANGED, BYTE-FOR-BYTE, and that is asserted rather than assumed. Base defaults are dev's LIVE values (verified against the running cluster: BSL bucket=velero with NO prefix, region us-east-1; all three CNPG Clusters ContinuousArchiving=True at s3://cnpg on the MinIO), and the dev overlay now restates all five explicitly for the same reason LONGHORN_DATA_PATH is restated — a silent drift in base would ORPHAN the backups dev's PROVEN restore depends on. The empty-prefix case was the one real risk, and it is settled empirically: with prefix "" the chart omits objectStorage.prefix from the rendered BackupStorageLocation ENTIRELY (helm template, chart 12.1.0), so dev's live BSL is unchanged, not merely equivalent. R2's TWO GOTCHAS, both wired up front: - region must be exactly `auto`. head-bucket answers {"BucketRegion":"WNAM"}, which is a PHYSICAL LOCATION HINT, not a signing region. This was hardcoded us-east-1 inside the Velero HelmRelease — correct-by-accident for MinIO, wrong for anything else — so it is a knob now. - checksumAlgorithm: "". velero-plugin-for-aws v1.14.2 bundles an AWS SDK with flexible checksums on by default and sends x-amz-sdk-checksum-algorithm / x-amz-checksum-crc32 on every PUT; R2 rejects those with HTTP 400 InvalidArgument, failing every backup and every kopia blob upload. It must be PRESENT-but-empty (the plugin branches on the key existing), and the chart does emit an empty value — verified by rendering it. Harmless against MinIO, so it is unconditional rather than a fourth knob. WHAT THIS DOES NOT DO. Velero stays SUSPENDED on prod. `spec.suspend: true` is owned by field manager `flux` (verified: kustomize-controller's managedFields do not include f:suspend), so server-side apply will not strip it, and nothing here declares suspension — which would also trip R-ENV-03, since a prod overlay may patch only cluster-vars and a Flux Kustomization's `decryption`. Unsuspending is the operator's, after `standup.sh --s3-endpoint <r2> s3check` proves a round trip. NO DNS KNOB IS TOUCHED. BASE_DOMAIN stays prod.home.keithjackson.dev and every EXTERNALDNS_* value is untouched. The apex inversion on work/prod-standup-campaign was deliberately NOT carried: this branch ports that branch's R2 reasoning knob by knob, and merges nothing. VERIFIED: ci/l0.sh green (flux-postbuild-substitution 272 assertions, 0 hazards, 33 knobs defined / 28 referenced, every new token resolved in BOTH overlays); render-golden, lint, schema, spec-immutability green; touched requirement R-STATE-03 covered. Refs R-STATE-03, R-IDP-05, R-ENV-02, R-ENV-03. Co-Authored-By: Claude Opus 5 <[email protected]>
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@@ -96,9 +96,22 @@ data:
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#
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# Substitution coverage (verify before adding a knob here): every path that consumes these declares
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# postBuild.substituteFrom cluster-vars — platform (K3S_API_HOST), platform-config
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# (CILIUM_LB_POOL_*, S3_BACKUP_ENDPOINT), crafty (CRAFTY_L4_VIP), apps-wave-0 (S3_BACKUP_ENDPOINT),
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# velero (S3_BACKUP_ENDPOINT), apps-vms (UNIFI_L4_VIP). A ${TOKEN} in an UNSUBSTITUTED path would
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# ship the literal string into the cluster.
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# (CILIUM_LB_POOL_*, and keycloak-db's S3_BACKUP_ENDPOINT + CNPG_BACKUP_PATH: the Cluster lives at
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# platform/keycloak/postgres-cluster.yaml but is rendered by platform-config, which is the ONLY
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# tier that lists it), crafty (CRAFTY_L4_VIP), apps-wave-0 (nextcloud-db + semaphore-db:
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# S3_BACKUP_ENDPOINT, CNPG_BACKUP_PATH), velero (S3_BACKUP_ENDPOINT, S3_BACKUP_REGION,
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# VELERO_BACKUP_BUCKET, VELERO_BACKUP_PREFIX), apps-vms (UNIFI_L4_VIP). A ${TOKEN} in an
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# UNSUBSTITUTED path would ship the literal string into the cluster.
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#
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# ADDING A KNOB IS SAFE UNDER StrictPostBuildSubstitutions ONLY BECAUSE OF THE ROOT EDGE. An
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# UNDEFINED variable is a HARD Kustomization failure, so a manifest that references a knob the
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# live ConfigMap does not yet carry breaks its whole tier. `clusters/base/platform.yaml` gained
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# `dependsOn: [flux-system]` for exactly this: dependsOn is REVISION-gated, so no substituting
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# tier can reconcile revision N until the ROOT Kustomization has APPLIED revision N — i.e. until
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# the new cluster-vars key EXISTS. Every substituting consumer chains transitively through
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# `platform`, so one edge covers the graph, and a new knob plus its first reference may ship in
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# ONE commit. (A hand-run `kubectl apply -k clusters/<env>` bypasses that ordering entirely: apply
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# the overlay BEFORE the tier that references the knob, or the tier fails until it retries.)
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# k3s API endpoint Cilium's kube-proxy replacement dials (platform/cilium/helmrelease.yaml).
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#
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@@ -150,9 +163,21 @@ data:
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# Off-cluster S3 backup target (R-STATE-03, R-IDP-05) — the on-Proxmox MinIO, plain HTTP, path-style.
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# Consumed by BOTH backup paths: every CNPG Cluster's barmanObjectStore.endpointURL (keycloak-db,
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# nextcloud-db, semaphore-db) and Velero's backupStorageLocation s3Url. Full URL incl. scheme+port.
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# Prod needs its OWN target: a backup that lands on the dev LAN's MinIO is not off-cluster DR.
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# Prod needs its OWN target: a backup that lands on the dev LAN's MinIO is not off-cluster DR —
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# and, measured 2026-09-05 from a pod INSIDE prod, it CANNOT reach it anyway (prod is on the SOHO
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# network 192.168.2.0/24, which is pfSense's WAN, while this MinIO sits inside pfSense's LAN:
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# `curl http://192.168.1.9:9000/minio/health/live` timed out after 15s). Prod uses Cloudflare R2.
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S3_BACKUP_ENDPOINT: "http://192.168.1.9:9000"
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# S3 region. Every S3 client REQUIRES one; MinIO ignores whatever it is; Cloudflare R2 demands
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# exactly `auto` (its `head-bucket` reports the physical hint `WNAM`, which is NOT a usable region
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# string). This was hardcoded `us-east-1` inside platform/velero/helmrelease.yaml — correct-by-
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# accident for MinIO and wrong for anything else, which is why it is a knob now. The base default
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# is dev's LIVE value, deliberately: dev's Velero has been signing requests with `us-east-1`
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# against that MinIO since bootstrap, and this repo's rule is that base == the known-good dev
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# value. Prod overrides to `auto`.
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S3_BACKUP_REGION: "us-east-1"
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# --- storage (ADR-0003) ---
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LONGHORN_DEFAULT_REPLICA_COUNT: "3" # default StorageClass replica count (3 on 3 nodes)
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# Longhorn's defaultDataPath (platform/longhorn/helmrelease.yaml): the on-NODE directory every
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@@ -205,6 +230,50 @@ data:
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VELERO_BACKUP_SCHEDULE: "0 3 * * *" # cron; overlays may differ
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VELERO_RETENTION: "168h" # dev short | prod long
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# ==========================================================================================
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# OBJECT-STORE TENANCY — the three knobs that keep two clusters and two backup tools from
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# writing into each other's data. THESE ARE SAFETY KNOBS, not preferences.
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# ==========================================================================================
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# Nothing about the object layout was per-environment before this: Velero's bucket was the
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# hardcoded literal `velero` with no prefix, and every CNPG Cluster used the hardcoded
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# `s3://cnpg` with barman's `serverName` defaulting to the CLUSTER NAME — and BOTH environments
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# have a keycloak-db, a nextcloud-db and a semaphore-db. Point two clusters at one bucket under
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# that layout and:
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# (a) each cluster's Velero ADOPTS the other's backups and TTL-DELETES them on retention; and
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# (b) two different Postgres servers stream WAL into ONE Barman prefix, which does not merely
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# mix files — it CORRUPTS THE CHAIN and destroys PITR for both. That is the worse half:
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# dev's DR restore is PROVEN (R-STATE-03) and this would silently un-prove it.
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#
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# WHY THERE IS NO SINGLE `S3_BACKUP_BUCKET`. The two consumers take differently-SHAPED values:
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# the Velero chart wants `bucket` and `prefix` as separate fields, while CNPG's
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# barmanObjectStore.destinationPath is ONE full s3:// URL whose first path segment IS the bucket.
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# CNPG's bucket therefore already lives inside CNPG_BACKUP_PATH; adding a second knob that had to
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# hold the same bucket name a second time would be a rotation waiting to drift — the exact class
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# of duplication this repo has been bitten by. Three knobs, each shaped for its own consumer, and
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# no two of them can contradict each other.
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#
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# BASE = DEV'S LIVE LAYOUT, BYTE-FOR-BYTE, AND MUST STAY THAT WAY. Dev's existing backups are at
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# `s3://velero/` (bucket root, no prefix) and `s3://cnpg/<clusterName>/` on that MinIO. Giving dev
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# a prefix, or renaming its buckets, would ORPHAN the very backups its proven restore depends on —
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# the same reason dev's EXTERNALDNS_TXT_OWNER_ID stays `default` and its LONGHORN_DATA_PATH stays
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# /var/lib/longhorn. Verified: with an EMPTY prefix the Velero chart omits `objectStorage.prefix`
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# from the rendered BackupStorageLocation entirely (helm template, chart 12.1.0), so dev's live
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# BSL is unchanged by this parameterization rather than merely equivalent to it.
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#
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# PROD, which has no history to preserve, gets ONE bucket with TWO disjoint top-level prefixes:
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#
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# s3://k3s-prod-backup/velero/… Velero (kopia repo + backup metadata)
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# s3://k3s-prod-backup/barman/<clusterName>/… CNPG WAL + base backups
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#
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# The operator created exactly one R2 bucket, so velero-vs-barman separation has to come from the
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# prefix rather than the bucket. The BUCKET ROOT IS DELIBERATELY LEFT EMPTY: if a prefix ever
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# renders wrong, its objects land somewhere obviously bogus instead of silently colliding with a
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# real tenant's data. Dev↔prod isolation is doubly independent — different endpoint AND different
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# bucket — so neither cluster can reach the other's objects even with a mis-substituted prefix.
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VELERO_BACKUP_BUCKET: "velero" # dev: the `velero` MinIO bucket | prod: k3s-prod-backup
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VELERO_BACKUP_PREFIX: "" # dev: bucket root (live layout) | prod: "velero"
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CNPG_BACKUP_PATH: "s3://cnpg" # dev: the `cnpg` MinIO bucket root | prod: s3://k3s-prod-backup/barman
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# --- placement ---
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PLATFORM_NODE_SELECTOR_KEY: "kubernetes.io/os" # base no-op selector; prod may pin roles
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PLATFORM_NODE_SELECTOR_VALUE: "linux"
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