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fix(vpn): disable vpn-egress — network blackholes PIA IPs (not ports/MTU/cluster)

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Decisive diagnosis: OpenVPN's outbound init packets are 14 bytes with zero
replies (so MTU was never the blocker), pod UDP egress is healthy (NTP replies),
but TCP 501/443 to PIA IPs time out while Google/Cloudflare are OPEN — across many
PIA servers. This 192.168.2.x WiFi segment blackholes PIA's IP ranges (and
intercepts DNS). Not code-fixable. Reverted the port/MTU red-herring env to PIA
defaults; disabled vpn-egress pending an operator network fix (move to the
unfiltered 192.168.1.x LAN, or unblock PIA on the router). Full trace in
DECISIONS-LOG.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
This commit is contained in:
jakman85andClaude Opus 4.8 committed 2026-08-22 18:15:11 -05:00
1 parent 9fc117e06d
commit 95a55952cc
4 files changed
+34 -21
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platform/kustomization.yaml
+7 -5
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@@ -17,11 +17,13 @@ resources:
- cert-manager # Let's Encrypt DNS-01 wildcard — needs SOPS `cloudflare-api-token`
- externaldns # auto DNS records — needs SOPS `cloudflare-api-token`
- gateway # Gateway API listeners (ingress; replaces Traefik)
# ---- Phase 3 — Egress / VPN (PIA OpenVPN-UDP, ADR-0013 amendment). Root cause of earlier failures:
# Cilium VXLAN gives pods MTU 1450 (node/host/WAN all 1500), so OpenVPN's 1500-byte handshake
# packets were dropped. Fix: OPENVPN_MTU/MSSFIX=1350 in gluetun-gateway.yaml so packets fit 1450.
# See DECISIONS-LOG "Phase 3 VPN". ----
- vpn-egress # shared Gluetun PIA/OpenVPN-UDP egress gateway + kill-switch (ADR-0013)
# ---- Phase 3 — Egress / VPN — DISABLED: BLOCKED at the network (operator action needed). Definitive
# finding: this 192.168.2.x WiFi segment BLACKHOLES traffic to PIA's IP ranges — TCP 501/443 to PIA
# time out, UDP + ICMP get no reply across many PIA servers, while Google/Cloudflare work on all.
# It also intercepts DNS/:53. Not MTU, not ports, not the cluster — the config is correct. Fix at
# the network (move to the unfiltered 192.168.1.x LAN / wired, or unblock PIA on the router), then
# re-enable. See DECISIONS-LOG "Phase 3 VPN — network blocks PIA". ----
# - vpn-egress # re-enable once the network permits PIA (no code change needed)
# ---- Phase 4 — Observability (creds provisioned via SOPS: grafana-admin, alertmanager-smtp) ----
- monitoring # kube-prometheus-stack + Loki + Alloy + Alertmanager
# ---- Later phases: enabled when their phase opens ----