phase2-prep: per-component no-secret rollout + component hardening (author-first)

Prep only — nothing deployed; running cluster untouched.

Reconciliation graph (operator-approved Option A): author clusters/dev/rollout/
= 4 per-component Flux Kustomizations (kyverno->cilium->longhorn->monitoring,
monitoring dependsOn longhorn). Dev overlay $patch:delete's the monolithic base
platform/apps and adds ./rollout, so only the no-secret tier reconciles; the
secret-blocked components are simply not created until hand-offs arrive. The
no-secret tier carries no SOPS content, so it needs no sops-age key. prod is
untouched (still builds the monolith). Convergence path coded in (delete rollout/
+ the two deletes) — R-ENV-02 divergence flagged for architect review.

Component hardening via cluster-vars (prod keeps strict posture):
- KYVERNO_VALIDATION_ACTION Enforce->Audit(dev), _WEBHOOK_FAILURE_POLICY
  Fail->Ignore(dev), _ADMISSION_REPLICAS 3->1(dev); webhook namespaceSelector
  excludes system+platform namespaces.
- MONITORING_STORAGE_CLASS var; GRAFANA_ADMIN_SECRET var (dev ''=chart default);
  Alertmanager SMTP/secret deferred to Phase-4 with verbatim re-enable markers.

Cilium parity verified against the live CNI (no-op adopt). Validated:
kubectl kustomize dev/prod/all-components, envsubst->YAML parse, make -C ci gate PASS.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>

clusters/dev/kustomization.yaml

@@ -2,39 +2,38 @@
 # clusters/dev — the ACTIVE build target overlay.
 #
 # `flux bootstrap ... --path=clusters/dev` points the dev cluster's Flux here.
-# This overlay adds NO resources of its own. Its ONLY job is to patch the shared cluster-vars
-# ConfigMap with dev-scoped values (R-ENV-02). The base reconciliation graph is reused verbatim.
+# TRANSITIONAL (Phase-2 bootstrap): this overlay reuses the base source + cluster-vars, but
+# REPLACES the monolithic base `platform`/`apps` Kustomizations with a per-component NO-SECRET
+# rollout (./rollout) — so dev brings up cilium/longhorn/monitoring/kyverno in order WITHOUT
+# dragging in the secret-blocked components. It patches cluster-vars with dev values (R-ENV-02)
+# and softens Kyverno for bootstrap. CONVERGENCE: delete ./rollout + the two $patch:delete
+# below to return to the unified base graph once all operator hand-offs land. See DECISIONS-LOG.
 apiVersion: kustomize.config.k8s.io/v1beta1
 kind: Kustomization
 resources:
   - ../base
+  - rollout
 patches:
-  # --- SOPS decryption + bootstrap source (PM-inlined from bootstrap/flux/patches/, 2026-08-16) ---
-  # Inlined (not cross-dir file refs) to stay within kustomize's default load restrictions.
-  # Realises the commented decryption TODOs in clusters/base and sets the real source URL.
-  # The `sops-age` Secret is created out-of-band (bootstrap/sops/install-age-key.sh) — name only.
+  # --- Drop the monolithic base platform/apps Kustomizations. They reconcile ALL 11 components
+  #     as one unit (incl. secret-blocked cert-manager/externaldns/velero/keycloak/oauth2-proxy/
+  #     image-automation/gateway/kubevirt); ./rollout replaces them with the per-component
+  #     no-secret set for dev bootstrap. Remove these two deletes to re-adopt the unified graph.
+  #     (No decryption patch is needed here: the rollout components carry no SOPS content, so
+  #     the `sops-age` Secret is not required for the dev bootstrap tier.) ---
   - patch: |-
+      $patch: delete
       apiVersion: kustomize.toolkit.fluxcd.io/v1
       kind: Kustomization
       metadata:
         name: platform
         namespace: flux-system
-      spec:
-        decryption:
-          provider: sops
-          secretRef:
-            name: sops-age
   - patch: |-
+      $patch: delete
       apiVersion: kustomize.toolkit.fluxcd.io/v1
       kind: Kustomization
       metadata:
         name: apps
         namespace: flux-system
-      spec:
-        decryption:
-          provider: sops
-          secretRef:
-            name: sops-age
   - patch: |-
       apiVersion: source.toolkit.fluxcd.io/v1
       kind: GitRepository
@@ -84,3 +83,18 @@ patches:
       - op: replace
         path: /data/VELERO_RETENTION
         value: "72h"
+      # dev-softened Kyverno for cold-start (base defaults Enforce/Fail/3 = prod posture).
+      - op: replace
+        path: /data/KYVERNO_VALIDATION_ACTION
+        value: "Audit"
+      - op: replace
+        path: /data/KYVERNO_WEBHOOK_FAILURE_POLICY
+        value: "Ignore"
+      - op: replace
+        path: /data/KYVERNO_ADMISSION_REPLICAS
+        value: "1"
+      # dev: no Grafana admin Secret yet → empty makes the chart use its default admin password
+      # (dev-only, NAT-isolated). Prod keeps the by-name SOPS secret from the base default.
+      - op: replace
+        path: /data/GRAFANA_ADMIN_SECRET
+        value: ""

clusters/dev/rollout/cilium.yaml

@@ -0,0 +1,25 @@
+---
+# Cilium — ADOPT the running Ansible-installed CNI. Parity between platform/cilium and the
+# live config was verified (k8sServiceHost/port via pod env, kube-proxy-replacement, gateway-api,
+# egress+bpf masquerade, hubble, l2, cgroup, v1.16.5) → this reconcile is a NO-OP.
+# prune: false — Cilium was bootstrapped out-of-band; adopt its config, never own-delete the CNI.
+# No decryption (no SOPS content). No dependsOn (it is the datapath everything else rides on).
+apiVersion: kustomize.toolkit.fluxcd.io/v1
+kind: Kustomization
+metadata:
+  name: cilium
+  namespace: flux-system
+spec:
+  interval: 30m
+  retryInterval: 2m
+  timeout: 10m
+  prune: false
+  wait: true
+  sourceRef:
+    kind: GitRepository
+    name: flux-system
+  path: ./platform/cilium
+  postBuild:
+    substituteFrom:
+      - kind: ConfigMap
+        name: cluster-vars

clusters/dev/rollout/kustomization.yaml

@@ -0,0 +1,20 @@
+---
+# Phase-2 NO-SECRET incremental rollout — DEV bootstrap scaffold.
+#
+# Per-component Flux Kustomizations for the components that need NO operator secret:
+#   kyverno (admission, dev-softened) · cilium (adopt running CNI) · longhorn (storage)
+#   · monitoring (dependsOn longhorn).
+# Secret-blocked components (cert-manager, externaldns, gateway, velero, keycloak,
+# oauth2-proxy, image-automation, kubevirt) are intentionally NOT created until their
+# operator hand-offs arrive (DECISIONS-LOG A2 / hand-off table).
+#
+# TRANSITIONAL: this is the dev bootstrap graph. Once every hand-off lands, dev drops
+# ./rollout and re-adopts the unified base monolith (clusters/base/platform.yaml) so dev
+# and prod share one reconciliation graph again (R-ENV-02 convergence). See DECISIONS-LOG.
+apiVersion: kustomize.config.k8s.io/v1beta1
+kind: Kustomization
+resources:
+  - kyverno.yaml       # first: admission present (Audit/Ignore in dev — non-blocking) before workloads
+  - cilium.yaml        # adopt the running CNI (parity verified — no-op reconcile)
+  - longhorn.yaml      # storage; monitoring depends on its StorageClass
+  - monitoring.yaml    # dependsOn longhorn

clusters/dev/rollout/kyverno.yaml

@@ -0,0 +1,25 @@
+---
+# Kyverno — in-cluster admission enforcer. DEV-SOFTENED via cluster-vars:
+#   KYVERNO_VALIDATION_ACTION=Audit, KYVERNO_WEBHOOK_FAILURE_POLICY=Ignore,
+#   KYVERNO_ADMISSION_REPLICAS=1 (base defaults Enforce/Fail/3 for prod).
+# Non-blocking on today's cluster (policies match only `app-namespace=true` namespaces,
+# none exist yet). No SOPS content. Listed first so admission is present before workloads.
+apiVersion: kustomize.toolkit.fluxcd.io/v1
+kind: Kustomization
+metadata:
+  name: kyverno
+  namespace: flux-system
+spec:
+  interval: 1h
+  retryInterval: 2m
+  timeout: 10m
+  prune: true
+  wait: true
+  sourceRef:
+    kind: GitRepository
+    name: flux-system
+  path: ./platform/kyverno
+  postBuild:
+    substituteFrom:
+      - kind: ConfigMap
+        name: cluster-vars

clusters/dev/rollout/longhorn.yaml

@@ -0,0 +1,25 @@
+---
+# Longhorn — block storage / CSI (default `longhorn` StorageClass). No SOPS content.
+# No dependsOn. The bulk-NFS StorageClass in this component carries REPLACE-ME (OQ-2) but is
+# an isolated, unreferenced object — it does NOT block Longhorn's HelmRelease reconcile.
+# PRE-DEPLOY CHECK (runtime, out of git): confirm `iscsid` active + /var/lib/longhorn mounted
+# on all 3 nodes (cloud-init provides both; verify after the T-1.5 rebuild).
+apiVersion: kustomize.toolkit.fluxcd.io/v1
+kind: Kustomization
+metadata:
+  name: longhorn
+  namespace: flux-system
+spec:
+  interval: 10m
+  retryInterval: 2m
+  timeout: 10m
+  prune: true
+  wait: true
+  sourceRef:
+    kind: GitRepository
+    name: flux-system
+  path: ./platform/longhorn
+  postBuild:
+    substituteFrom:
+      - kind: ConfigMap
+        name: cluster-vars

clusters/dev/rollout/monitoring.yaml

@@ -0,0 +1,26 @@
+---
+# Monitoring — kube-prometheus-stack + Loki + Alloy. Prometheus/Loki PVCs bind the
+# `longhorn` StorageClass, so this dependsOn longhorn (Flux waits for it Ready first).
+# Grafana admin password (chart default in dev) and Alertmanager SMTP (deferred to the
+# Phase-4 hand-off) are handled WITHOUT an operator secret in dev → NO decryption block.
+apiVersion: kustomize.toolkit.fluxcd.io/v1
+kind: Kustomization
+metadata:
+  name: monitoring
+  namespace: flux-system
+spec:
+  interval: 10m
+  retryInterval: 2m
+  timeout: 15m
+  prune: true
+  wait: true
+  dependsOn:
+    - name: longhorn
+  sourceRef:
+    kind: GitRepository
+    name: flux-system
+  path: ./platform/monitoring
+  postBuild:
+    substituteFrom:
+      - kind: ConfigMap
+        name: cluster-vars