Adds conformance/tests/l0-static/flux-postbuild-substitution/ — an offline, stdlib-only
L0 check tagged R-ENV-02 + R-GITOPS-01 (deliberately NOT R-TEST-01, which would
overclaim). It reuses lib/status.py's `resources:` walk rather than forking it, so "what a
path renders" has exactly one definition. It asserts: every ${...} on a substituted path
is defined-or-escaped (comments included); no default-operator form on an undefined name;
no unparseable expansion; the rendering path actually substitutes cluster-vars; every
overlay-patched /data/KEY has a base default; and that the gate itself is load-bearing.
WIRED AS AN UNCONDITIONAL STAGE (3c) in ci/l0.sh, and that matters: stage 3b scopes to
touched requirements, and ci/touched-requirements.sh maps only clusters/* to R-ENV-02 —
so an edit to a substituted manifest under apps/ or platform/ would have filtered this
check out of exactly the change that introduces the bug. l0 fail -> BLOCK=1 in gate.sh.
Mutation-tested all five assertion classes (undefined token, indexed expansion, :- form,
missing substituteFrom, un-wired gate); each fails as intended, baseline green.
STRICT MODE IS PROVEN SAFE TO ENABLE — measured, not inspected. For all 11 substituted
paths, `kubectl kustomize --load-restrictor LoadRestrictionsNone <path> | flux envsubst
--strict` exits 0 against cluster-vars base defaults. Negative control confirms the
incident: with K3S_API_HOST unset, non-strict renders k8sServiceHost empty while strict
exits 1 with `variable not set (strict mode)`. The feature gate itself is NOT flipped
here — that is a live-cluster change and the operator's call.
Escapes the six comment hazards that stood in the way (apps/vms/unifi x4,
platform/longhorn x2). All were prose ABOUT the escaping convention; since the repo's own
contract is that $${...} emits a literal ${...}, escaping them is both precise and
self-consistent. kustomize strips these particular comments today, but comment survival is
an implementation detail — a body comment carrying $ WAS observed surviving into built
apps/wave-1 — and a survivor would kill the whole Kustomization.
DOCTRINE CORRECTED (measured against flux 2.4.0): clusters/base/apps-vms.yaml claimed an
indexed expansion is fatal "escaped or not". Escaping is TOTAL — $${ARR[0]} emits the
literal text safely; only the UNESCAPED indexed form is fatal. Corrected in place.
Also empties DOCUMENTED_GAPS in conformance/run.sh with rationale: R-ENV-02 and
R-GITOPS-01 now have a real verifying test, which run.sh's own comment named as the
trigger for removing them.
Advisory output (not failures): 6 dead cluster-vars knobs — BASE_DOMAIN, CLUSTER_ENV,
CLUSTER_POD_CIDR, PIA_REGION, PLATFORM_NODE_SELECTOR_{KEY,VALUE}. The last four are
documented reference-only; BASE_DOMAIN and CLUSTER_ENV look like genuine rot (hostnames
are hardcoded elsewhere) and are worth a follow-up.
Gate: MERGE GATE: PASS. 102 assertions, 0 hazards.
Serves: R-ENV-02, R-GITOPS-01.
Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
Root cause of a W5 wedge: default 5m Helm timeout on slow-HDD Longhorn upgrades caused
a rollback attempt after the data had already migrated to the new minor, which the old
manager fatally refuses. Give the upgrade room and never auto-rollback (fail forward).
Co-Authored-By: Claude Opus 4.8 <[email protected]>
Gateway API CRDs bumped v1.2.1->v1.3.0 (required by Cilium 1.18; applied server-side).
Land on current k8s 1.32 before the 1.33 hop.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
Land the two pacing components on current k8s 1.31 before the 1.32 k3s hop.
Cilium 1.17 supports k8s 1.29-1.32; Longhorn 1.8 supports 1.25+; Gateway API CRDs
stay v1.2.1 (Cilium 1.17 targets v1.2.x). Also commits the full upgrade plan doc.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
The k3s VM disks are HDD-backed, so a full Longhorn replica rebuild's
sequential I/O can saturate the spindle and starve etcd's WAL fsync,
crash-looping etcd and flapping the kube-vip VIP (observed during a
rolling node resize). Cap rebuilds to one replica per node at a time so a
node bounce or replica replenishment can never storm the disks.
Set via HelmRelease defaultSettings.concurrentReplicaRebuildPerNodeLimit
(GitOps-managed, permanent). replica-replenishment-wait-interval stays at
the Longhorn default of 600s. Reference values.yaml kept in sync.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
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).
jakman85andClaude Opus 5