From 4f74c8a2f0243bd11741aed67a8fd4157cc7766a Mon Sep 17 00:00:00 2001
From: Keith Jackson <keithallenjackson@gmail.com>
Date: Tue, 25 Aug 2026 08:45:12 -0500
Subject: [PATCH] chore(storage): Longhorn over-provisioning 100->200% +
 right-size plex config 20->8Gi

The 39Gi/node Longhorn data disks at 1:1 over-provisioning can't fit the media stack
(plex 20Gi replica failed: 'insufficient storage'). Volumes are thin-provisioned config-only,
so 200% lets the full catalog fit without a disk resize; physical fill risk is low. Also
right-sized plex config (20Gi was excessive for metadata). Prod-grade path: grow the data
disks (WS-STORAGE follow-up).
---
 apps/plex.yaml                     | 2 +-
 catalog/plex.yaml                  | 2 +-
 platform/longhorn/helmrelease.yaml | 6 ++++--
 3 files changed, 6 insertions(+), 4 deletions(-)

diff --git a/apps/plex.yaml b/apps/plex.yaml
index 0eb3bff..ec1ef80 100644
--- a/apps/plex.yaml
+++ b/apps/plex.yaml
@@ -49,7 +49,7 @@ spec:
   storageClassName: longhorn
   resources:
     requests:
-      storage: 20Gi
+      storage: 8Gi
 ---
 # Deployment (R-PLAT-02)
 apiVersion: apps/v1
diff --git a/catalog/plex.yaml b/catalog/plex.yaml
index fccbf17..f90cc20 100644
--- a/catalog/plex.yaml
+++ b/catalog/plex.yaml
@@ -27,7 +27,7 @@ exposure: public              # edge port-forward + public DNS; clients + Seerr
 egress: internet              # normal WAN egress (docs/03; R-NET-05)
 storage:
   - name: config
-    size: 20Gi
+    size: 8Gi
     class: longhorn           # Plex DB/metadata: replicated app state on the 3-replica tier (docs/04; R-STATE-01/02)
 dependencies: []              # default-deny: reaches only DNS; clients/Seerr reach IT (docs/03; R-NET-01/02)
 ingressRoutes:
diff --git a/platform/longhorn/helmrelease.yaml b/platform/longhorn/helmrelease.yaml
index f6e8ebb..df7c409 100644
--- a/platform/longhorn/helmrelease.yaml
+++ b/platform/longhorn/helmrelease.yaml
@@ -62,8 +62,10 @@ spec:
       storageReservedPercentageForDefaultDisk: "20"
       # Stop scheduling new replicas onto a disk once free space drops below 25%.
       storageMinimalAvailablePercentage: "25"
-      # Dev: no thin over-provisioning — requested capacity must physically fit (1:1).
-      storageOverProvisioningPercentage: "100"
+      # Dev: 200% thin over-provisioning — config-only volumes use little actual space, so the small
+      # 39Gi data disks host the full app catalog. Physical fill risk is low (watch monitoring PVCs).
+      # Prod-grade alternative: grow the Longhorn data disks and return to 1:1 (WS-STORAGE).
+      storageOverProvisioningPercentage: "200"
 
       # --- misc dev-appropriate defaults ---
       # Keep replicas spread for durability rather than co-locating with the pod.