docs(prod): open Phase 7 (prep only) + T-7.1 bare-metal provisioning checklist
The operator added the first production node (k3s-prod-1, 192.168.2.10 — HP EliteDesk 800 G5 Mini, i7-9700T/31GiB, Debian 13, VT-x + /dev/kvm) and opened roadmap Phase 7 for PREP WORK ONLY: no k3s install until the R-ENV-02 blockers close and the gate is green. Records the Phase-7 entry-gate position honestly: the operator has declared hardware ready, but "Phases 1-6 proven in dev/test" is NOT met (37/51 conformance; R-ENV-01/02/03 themselves uncovered). Proceeding is an explicit, accepted risk — not an oversight. Adds infra/PROD-PROVISIONING.md (T-7.1, design-only): firmware/BIOS, disk layout, OS, network, access, Ansible reuse, repo blockers, build sequence, Phase-7 exit criteria. Key findings recorded in DECISIONS-LOG: - R-ENV-02 is violated in the base — dev LAN addresses hardcoded into base manifests (cilium k8sServiceHost, the Cilium LB pool, crafty/UniFi LB IPs, 3 S3 backup endpoints). Prod is on 192.168.2.x, so prod would build WRONG today. - clusters/prod never sets GATEWAY_VIP -> would inherit the base default 10.73.0.240, an address on the RETIRED libvirt network. - No NOPASSWD sudo on the prod node -> all Ansible fails at its first become. - node_baseline device defaults are virtio (/dev/vdb,vdc) and absent on bare metal. - ESCALATION: agents/task-board.md is structurally unmaintainable — AGENTS.md designates it the one agent-editable surface, but ci/spec-immutability.sh fails the gate on ANY spec-repo dirt with no path exception. Explains the all-todo board after six phases. NOT worked around: exempting it would weaken an R-TEST-06 gate. Operator decision. Operator decisions: Phase 7 open (prep only); wait for all 3 nodes before cluster-init; check drive health before choosing the single-SSD disk layout. Serves: R-ENV-01, R-ENV-02, R-ENV-03, R-PLAT-01/03. Task: T-7.1. Gate: MERGE GATE: PASS. Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
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@@ -8,6 +8,12 @@ reconnects to it and re-establishes the toolchain.
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> `DECISIONS-LOG.md` entry (2026-08-31)** — it is the current-state + gotchas + prioritized **Next
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> Steps** handoff — and the plans under `docs/plans/`. Start at Next Steps.
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> **Phase 7 (prod) is OPEN as of 2026-08-31 — prep only.** The first prod node
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> (`k3s-prod-1`, `192.168.2.10`) is on the bench. This document covers the **dev** cluster;
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> for prod see [`PROD-PROVISIONING.md`](PROD-PROVISIONING.md) (T-7.1 checklist) and the
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> Phase-7 entry in `DECISIONS-LOG.md`. Nothing is installed on prod hardware until the
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> R-ENV-02 tokenization blockers close and the gate is green.
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> **History note.** The cluster was originally 3 libvirt/KVM VMs on the workstation
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> (`10.73.0.0/24` NAT). That was **retired** after the workstation ran out of RAM/disk; the cluster
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> now lives on **Proxmox VE**. Anything mentioning `virsh`, `qemu:///system`, `tofu`+`dmacvicar/libvirt`,
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@@ -0,0 +1,192 @@
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# Prod bare-metal provisioning checklist (T-7.1)
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**Task:** T-7.1 · **Workstream:** WS-INFRA · **Serves:** R-ENV-01, R-ENV-02, R-ENV-03, R-PLAT-01/03
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**Status:** Phase 7 **opened by the operator 2026-08-31** — *prep only*. Nothing is installed on prod
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hardware until the blockers in §7 are closed and `make -C ci gate` is green.
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> **Entry-gate note (recorded, not waived).** `roadmap/phases.md` gates Phase 7 on *"Phases 1–6
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> proven in dev/test; operator declares prod hardware ready."* The operator has declared hardware
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> ready. The first condition is **not** met: conformance is 37/51, and the uncovered set includes
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> **R-ENV-01/02/03** — the very requirements this document serves. We proceed with prep work
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> knowingly; see `DECISIONS-LOG.md` (2026-08-31 Phase-7 entry).
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Prod is **3× mini-PC bare metal** ([spec docs/02](../../home-network-k3s/docs/02-environments-and-provisioning.md)).
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The dev path (OpenTofu → Proxmox VM → cloud-init) **does not apply**: there is no hypervisor API to
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call. Stage 1 "Create" is a human imaging a box. Stages 2–4 (baseline, cluster-join, manage) reuse
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the *same* Ansible roles and the *same* Flux base as dev — that reuse is the R-ENV-02 obligation.
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---
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## 0. Node inventory
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Fill a row per node as it lands. Node 1 is as-found on 2026-08-31.
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| | node 1 | node 2 | node 3 |
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|---|---|---|---|
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| Hostname | `k3s-prod-1` | `k3s-prod-2` | `k3s-prod-3` |
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| LAN IP | `192.168.2.10` | — | — |
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| Model | HP EliteDesk 800 G5 Desktop Mini | | |
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| CPU | i7-9700T, 8c/8t, VT-x | | |
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| RAM | 31 GiB | | |
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| Disks | 1× 477 GB SATA SSD (`C400-MTFDDAC512M`) | | |
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| OS | Debian 13 (trixie), kernel 6.12 | | |
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| Firmware | HP R21 Ver. 02.26.00 | | |
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| `/dev/kvm` | present | | |
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Dev nodes for comparison: 8 vCPU / 24 GiB / Debian 13, **two** dedicated data disks (Longhorn + etcd).
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---
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## 1. Firmware / BIOS (per node, before OS install)
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- [ ] **Virtualization enabled** — VT-x *and* VT-d. Required for KubeVirt (R-PLAT-03); verify after
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boot with `/dev/kvm` present and `grep -cE 'vmx|svm' /proc/cpuinfo` non-zero.
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- [ ] **AC power recovery = Power On.** A homelab node must return after a power cut without a
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human pressing the button. (`docs/02` calls out wake/boot behaviour explicitly.)
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- [ ] **Wake-on-LAN enabled** on the onboard NIC (remote recovery when the box is off).
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- [ ] **Boot order** — internal disk first; USB above it only while imaging. Disable network boot
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unless PXE is adopted.
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- [ ] **Secure Boot** — record the setting. k3s itself is fine either way; note it so all three
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nodes match.
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- [ ] **Firmware version recorded** in §0 and consistent across all three nodes.
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## 2. Disk layout — **OPEN DECISION, blocks the build**
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`docs/02` requires the OS-vs-Longhorn device split to be **documented before prod build**. Dev went
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further and added a *third* device for etcd after HDD contention starved etcd WAL fsync
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(`docs/plans/ssd-etcd-isolation.md`).
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Node 1 as-found is a **single** 477 GB SATA SSD carrying everything:
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```
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sda 477G C400-MTFDDAC512M (SSD, ~2011-era Micron/Crucial)
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├─sda1 976M /boot/efi
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├─sda2 30G /
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├─sda3 12G /var
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├─sda4 977M swap
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└─sda5 433G /srv <- the only large free space
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```
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Consequences to settle before imaging nodes 2 and 3:
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- [ ] **Drive health checked first** (operator decision, 2026-08-31). See §5 for the command —
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needs root. A ~15-year-old consumer SSD is not an obvious place for prod state.
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- [ ] **Decide the layout.** `roles/node_baseline` expects *block devices*
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(`node_baseline_longhorn_device`, `node_baseline_etcd_device`) and makes a filesystem on them.
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Its defaults `/dev/vdb` and `/dev/vdc` are **virtio names that do not exist on bare metal** —
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prod must override them in `group_vars`. On a single-disk node there is no second device at
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all, so one of:
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- **Add a second drive** (M.2 NVMe if the chassis has a free slot; verify physically — only a
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SATA controller is populated today). Cleanest: matches dev's isolation, gives etcd its own
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spindle.
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- **Use `/dev/sda5`** (the 433 GB `/srv` partition) as the Longhorn device, etcd stays on `/`.
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Buildable today, zero spend, but re-creates the shared-spindle contention dev was burned by.
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- **Repartition** into dedicated OS / etcd / Longhorn partitions. Better isolation, still one
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physical failure domain.
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- [ ] **All three nodes get the identical layout.** Longhorn replica placement assumes symmetry.
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- [ ] Record the chosen device paths here and set them in `inventory/group_vars/k3s_prod.yml`.
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## 3. OS install (per node)
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- [ ] **Debian 13 (trixie)**, matching dev exactly — same kernel series, same package baseline.
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- [ ] Hostname `k3s-prod-N`.
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- [ ] Partition per the §2 decision.
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- [ ] **No cloud-init needed.** Dev's first-boot work was deliberately moved into
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`roles/node_baseline` when provisioning became API-only (`infra/cloud-init/` is a README now),
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so the same role covers bare metal. Nothing to port.
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## 4. Network (per node)
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- [ ] **Static IP** on the prod LAN, recorded in §0. Node 1 is `192.168.2.10/24`, gateway
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`192.168.2.1`.
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- [ ] **Reserve the VIP addresses** before the build — prod needs its own kube-vip control-plane VIP
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*and* its own Cilium L2 announcement pool for ingress. Neither exists yet (§7).
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- [ ] **Resolver: configure at least two upstreams.** Node 1 currently has a single IPv4 nameserver
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(`192.168.2.1`). A single upstream is a known SPOF that has already bitten this project —
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it broke containerd image pulls and CoreDNS forwarding on dev. A fix exists but is **stranded
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unmerged** on `fix/node-dns-resilient-upstream`; land it, then apply the same pattern here.
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- [ ] Confirm the prod LAN's relationship to the dev LAN (`192.168.1.x`) and to the pfSense NAT —
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prod on `192.168.2.x` sits on the *workstation* side of the boundary dev lives behind.
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## 5. Access (per node) — **blocks all Ansible**
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- [ ] **`k3s` user with the `home_network` SSH key.** Working on node 1.
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- [ ] **NOPASSWD sudo.** *Not configured on node 1* — `sudo -n` demands a password, so every
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playbook fails at its first `become` task. Dev nodes have this; prod must match:
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```bash
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# on the node, as a user who can already sudo:
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echo 'k3s ALL=(ALL) NOPASSWD:ALL' | sudo tee /etc/sudoers.d/90-k3s
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sudo chmod 0440 /etc/sudoers.d/90-k3s
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sudo visudo -c
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```
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- [ ] **Drive health baseline** (§2), needs root:
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```bash
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sudo apt-get update && sudo apt-get install -y smartmontools
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sudo smartctl -a /dev/sda # Power_On_Hours, Percent_Lifetime_Remaining, reallocated sectors
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```
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## 6. Ansible baseline & cluster join
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Reuses the dev roles unchanged — that reuse **is** R-ENV-02. Only inventory and group_vars differ.
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- [ ] Add a `k3s_prod` inventory group (`k3s_prod_primary` / `k3s_prod_secondary`). Prod is reached
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**directly** on the LAN — no NAT port-forward hop, unlike dev's `192.168.2.102:225x` mapping.
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- [ ] `group_vars/k3s_prod.yml`: `kube_vip_address`, `cluster_controller_api_server`, and the §2
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device overrides for `node_baseline_longhorn_device` / `node_baseline_etcd_device`.
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- [ ] Run `playbooks/node-baseline.yml` → packages, kernel modules, sysctls, iscsid, data-disk
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filesystems + mounts. (`qemu-guest-agent` is a no-op on bare metal — the role already only
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*starts* it when the virtio channel exists, so it degrades cleanly.)
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- [ ] Run `playbooks/k3s.yml` → HA embedded etcd, flannel/kube-proxy/Traefik/servicelb disabled.
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**Only once all three nodes are present** — see §8.
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- [ ] Run `playbooks/kube-vip.yml` → control-plane VIP on the prod LAN.
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- [ ] Run `playbooks/cilium.yml` → CNI at bootstrap; Flux's HelmRelease adopts it afterwards. The
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bootstrap values and the HelmRelease **must stay in parity** (`kubeProxyReplacement`,
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`k8sServiceHost`/`Port`) or the two layers fight over CNI config (`docs/02`).
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- [ ] Decide whether prod runs a VPN egress gateway node (dev uses `k3s-dev-3`, ADR-0015).
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## 7. Repo blockers — **prod cannot be reconciled until these land**
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`clusters/prod` is design-only today and **would build wrong**. R-ENV-02 promises dev and prod differ
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*only* by `cluster-vars` values; in practice dev LAN addresses are hardcoded into base manifests:
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| Hardcoded value | Where | Prod needs |
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|---|---|---|
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| `k8sServiceHost: 192.168.1.50` | `platform/cilium/helmrelease.yaml:50`, mirrored in `values.yaml:16` | prod primary node IP |
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| LB pool `192.168.1.53–.60` | `platform-config/cilium/l2-ip-pool.yaml:15` | a prod-LAN pool |
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| `192.168.1.55` (crafty) | `platform/crafty/service-l4.yaml` | prod-LAN address |
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| `192.168.1.54` (UniFi VM) | `apps/vms/unifi/50-service-l4.yaml` | prod-LAN address |
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| `192.168.1.9:9000` (S3 backup) | `platform/keycloak/postgres-cluster.yaml`, `apps/wave-0/{nextcloud,semaphore}-db.yaml` | reachable prod backup target |
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- [ ] **Tokenize each into a `cluster-vars` knob** with a base default, then set the value in *both*
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overlays. Adding a knob before referencing `${KNOB}` is the sanctioned mechanism (see the
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header comment in `clusters/base/cluster-vars.yaml`). `platform`, `platform-config`, the app
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waves, `apps-vms` and `crafty` all already carry `postBuild.substituteFrom: cluster-vars`, so
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the seam exists.
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- [ ] **`clusters/prod` must set `GATEWAY_VIP`.** It currently doesn't, so prod would inherit the
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base default `10.73.0.240` — an address from the **retired libvirt network**. The base file's
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own comment flags this as owed "when hardware is built."
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- [ ] **Dev overlay sets every new knob to today's exact value** so rendered dev output is
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byte-identical and the live cluster sees zero drift. Verify with `make -C ci render-golden`.
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- [ ] Confirm prod's backup target: dev's S3 (`versitygw` on the Proxmox host, `192.168.1.9`) is on
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the dev side of the network. Off-cluster backup is DR-critical (R-STATE-03).
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## 8. Build sequence (operator decision, 2026-08-31: **wait for all three nodes**)
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Node 1 is baselined now; the cluster is **not** initialized until nodes 2 and 3 are on the bench.
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This keeps prod spec-conformant (3-node HA embedded etcd) from its first boot, avoids a
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single-server-etcd window, and avoids a later member-add dance.
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1. Per-node §1–§5 on each of the three boxes.
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2. §7 repo work lands on `main` with the gate green.
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3. `node-baseline` → `k3s` (all three) → `kube-vip` → `cilium`.
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4. `flux bootstrap ... --path=clusters/prod`.
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5. Conformance against prod (§9).
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## 9. Exit criteria (Phase 7)
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- [ ] Prod runs the same config as dev via the prod overlay, **no base edits** (R-ENV-02).
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- [ ] Node destroy/rebuild from IaC + Ansible without data loss (R-ENV-01, R-STATE-01).
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- [ ] Full **automated** prod DR drill (R-STATE-03) — `definition-of-done.md` requires this for prod
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specifically.
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- [ ] Monitoring and alerts live on prod.
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- [ ] The conformance suite passes green **against the prod cluster**, not just dev (R-TEST-03).
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