Commit Graph
76 Commits
Author SHA1 Message Date
jakman85 49d82491dd docs(prod): node 2 memory SOLVED — Linux 6.12 EFI memattr bug, NOT a hardware fault
I framed this as an OPEN HARDWARE FAULT and blamed, in order: the DIMM, BIOS memory remapping,
and stale Fast Boot memory-training data. ALL THREE WERE WRONG. The hardware is fine.

ROOT CAUSE: HP's R21 firmware publishes a CORRUPT EFI Memory Attributes Table, and Linux 6.12
fails to validate it before reserving memory from its contents. drivers/firmware/efi/memattr.c
never validates num_entries or desc_size:

    if (tbl->version > 2) { pr_warn(...); goto unmap; }
    tbl_size = sizeof(*tbl) + tbl->num_entries * tbl->desc_size;
    memblock_reserve(efi_mem_attr_table, tbl_size);

Garbage version > 2 -> kernel bails, memory intact. Garbage version <= 2 -> kernel multiplies two
garbage fields and reserves GIGABYTES from the table address to the top of RAM.

THE EVIDENCE THAT SETTLES IT: the same machine — same DIMM, same BIOS, same kernel, same cmdline —
booted with the FULL 15.9 GiB two boots earlier, with a byte-identical BIOS-e820 map. Boot -2:
15,917,744K available, 615,208K reserved, 'Unexpected EFI Memory Attributes table version
1463964749'. Boots -1/0: 2.6 GiB, 13.9 GiB reserved, 'Failed to map ... @ 0xbeeb0018'. No hardware
fault is intermittent in that shape or fixed by a reboot. MemTotal = DMA(3840) + DMA32(684481)
pages = 2,753,284 kB exactly, Normal contributing zero.

BOTH PROD NODES ARE AFFECTED. k3s-prod-1 prints 'Unexpected EFI Memory Attributes table version
1030' — also garbage, but >2, so the kernel bails and it keeps its 32 GiB BY LUCK, NOT IMMUNITY.
It is one unlucky boot from the identical fault. Dev nodes publish no memattr table at all
(Proxmox OVMF) and are unaffected.

FIX: kernel >= 6.13 — upstream 8fbe4c49c0cc 'efi/memattr: Ignore table if the size is clearly
bogus', whose commit message describes this verbatim. Verified absent from v6.12 and from current
linux-6.12.y. On Debian 13: linux-image-amd64 from trixie-backports.

DO NOT buy RAM, move the DIMM, RMA the board, or run memtest expecting failures. Rebooting,
disabling Fast Boot, clearing CMOS and unplugging USB are all the same lottery — they move where
the table lands and may LOOK like fixes.

Records every killed hypothesis with its disproof so none of them get re-run.

Serves: R-ENV-01, R-ENV-03. Task: T-7.1.
2026-09-01 22:14:14 -05:00
jakman85 5ea9c93f58 docs(prod): BIOS password answer + CORRECT the 0x4 'auth failure' reading
Operator asked for the default BIOS password. ANSWER: there is none, and no factory default
exists to look up. HP business desktops ship with no Setup and no Power-On password; the
is_enabled=0 we measured IS the factory state. Recovery for a forgotten password is the PSWD
jumper — and 'stringent security' must NOT be enabled, since HP documents that it removes the
physical bypass and turns a 5-minute fix into a signed per-serial HP service case.

CORRECTION, and the kernel driver misled me: I recorded that the firmware refused our write for
lack of BIOS-admin authentication. Wrong. hp-bioscfg passes the return of HP's WMI SetBIOSSetting
through hp_wmi_error_and_message(), which is THE ERROR TABLE FOR A DIFFERENT INTERFACE (the
"SECU" commands under HP_WMI_BIOS_GUID). Per HP's Client Management Interface white paper,
SetBIOSSetting 4 = 'Failed' (generic) and 6 = 'Access Denied'. We got 4, not 6 — and the driver
has a separate BIOS_ADMIN_NOT_SET = 0x38 -> -EPERM for the no-password case, which we also did
not get. 'Invalid command type' is the driver looking 4 up in the wrong table: a genuine upstream
bug worth reporting to platform-driver-x86.

Most likely real cause (inferred, testable): with an empty password the driver emits an UNTAGGED
empty UTF-16 string, while every HP-documented caller passes Password="<utf-16/>" even when
blank — the driver only prepends that prefix for a non-empty string. Setting a password may fix
writes, but by flipping onto the tagged code path, NOT because 0x4 meant unauthorised.

Also verified from source: hp-bioscfg CANNOT set a password. current_password and new_password
both funnel into store_password_instance(), which only strscpy's into driver RAM; new_password is
write-only into a buffer nothing ever reads.

Count corrected: 241 attributes exposed, 239 with a current_value, 215 non-empty. I had quoted
215 as the total; it was the non-empty subset.

Recommendation recorded: land read-only drift detection now (zero risk, no new credential, and it
already caught real drift); treat a Setup password as a deliberate experiment on node 3 only;
hp-repsetup as fallback but it needs Secure Boot off or a self-signed module; skip Sure Admin/BCU
at this scale.

Serves: R-ENV-03, R-SEC-01. Task: T-7.1.
2026-09-01 22:10:07 -05:00
jakman85 3a88abb958 docs(prod): iGPU ruled out as the cause; CORRECT my last_pfn misreading
Operator asked whether node 2's missing memory could be reserved for integrated graphics.
TESTED, and no: /proc/iomem shows 'c8800000-cc7fffff : Graphics Stolen Memory' = EXACTLY 64 MiB,
matching the BIOS Video Memory Size=64 MB setting, and it sits BELOW the 4 GiB line. The UHD 630
(i915 bound) takes precisely what it is configured to take. It cannot account for 13.3 GiB and is
not even in the affected address range.

CORRECTION to my own analysis, prompted by checking that hypothesis properly: I cited the
'last_pfn revised DOWN from 0x42f800 to 0xc3c10' line as evidence of a memory cap. That was a
MISREADING. x86 boot prints last_pfn twice — first max_pfn from the full e820, then max_low_pfn,
the end of RAM below 4 GiB. The e820 low usable region ends at 0xc3c0ffff, so the next PFN is
exactly 0xc3c10, which is the second value observed. It matches to the byte and is normal on any
machine with more than 4 GiB. I presented a routine boot message as a smoking gun, and the
'memory remapping above 4 GB not being applied' signature claim rested partly on it.

The real anomaly is narrower than first stated: the Normal zone is 'present' but 'managed 0',
13.3 GiB is reserved, and nothing in the boot log explains by what. Ruled out so far: DIMM health,
firmware inventory, memory-remap settings (none exist on this platform), MTRR trim, iomem
registration, and now integrated graphics. Leading remaining hypothesis is stale memory-training
data cached by Fast Boot — testable with one F10 toggle.

Serves: R-ENV-03. Task: T-7.1.
2026-09-01 21:54:12 -05:00
jakman85 9f7052ab2b docs(prod): fill in node-2 inventory; drop stale investigate bullets
Records node 2's as-found hardware alongside node 1 and removes two bullets that my earlier
edit left duplicated/obsolete (the BIOS comparison is done; clear-CMOS was listed twice).

Makes the hardware ASYMMETRY explicit in the table rather than buried in prose: node 1 is a
~2011 Micron C400 SATA SSD at 69% life with 15 grown bad blocks and 187 erase failures; node 2
is a Samsung PM9A1 NVMe at 96% life, PASSED. Same chassis, same BIOS, same CPU, same partition
layout — very different storage. §2 requires an identical disk layout across all three nodes
because Longhorn replica placement assumes symmetry, so this belongs in the inventory where the
disk decision will be made.

Serves: R-ENV-03. Task: T-7.1.
2026-09-01 21:45:37 -05:00
jakman85 3c8f809aaf docs(prod): CORRECTION — BIOS attributes are read-only in practice, not writable
I recorded that the hp-bioscfg attributes were 'writable from the OS' because current_value
has mode rw and no BIOS passwords are set. That was WRONG, and the firmware said so when the
write was actually attempted:

  hp_bioscfg: Returned error 0x4, "Invalid command type"   (surfaces as printf: I/O error)

HP requires BIOS-admin authentication for programmatic changes and neither credential is
provisioned on these nodes — Setup Password is_enabled=0 (role bios-admin), SPM
key_mechanism=not provisioned. Secure Boot is also enabled. File mode is not authority; the
firmware is.

What survives the correction, and it is the useful half: READS WORK. Diffing 215 attributes
between node 1 and node 2 is exactly how the drift in §0b was found — nobody spots
'After Power Loss=Power Off' by eye. So the §1 firmware checklist IS machine-CHECKABLE today
with reads alone, and node_health should assert it.

What does NOT survive: machine-ENFORCEABLE. Converging BIOS settings automatically would
require provisioning a BIOS Setup Password on every node — a stored credential that can rewrite
firmware. That is a real security decision and the operator's call, not something to default to.

Consequence for the node-2 memory fault: setting Fast Boot=Disable and After Power Loss=Power On
must be done in F10 on the box. Updated §0b and §1 accordingly.

Serves: R-ENV-03. Task: T-7.1.
2026-09-01 21:45:15 -05:00
jakman85 11b21f7347 docs(prod): BIOS settings compared programmatically via hp-bioscfg
Both nodes load the hp-bioscfg driver, exposing 215 BIOS attributes read/write at
/sys/class/firmware-attributes/. No BIOS passwords are set, so they are writable FROM THE OS.

RULED OUT as the cause of node 2's 2.6 GiB limit: firmware inventory is correct (BIOS itself
reports Memory Size=16384 MB); no memory-remap/above-4G attribute exists on this platform at
all; MTRRs are effectively identical with no trim warning; /proc/iomem registers the full
100000000-42f7fffff as System RAM and 127 memory blocks report online.

REAL DIFFERENCES FOUND (node1 works / node2 broken):
  After Power Loss          Power On  / Power Off   <- VIOLATES this document's own §1
  Fast Boot                 Disable   / Enable      <- leading hypothesis
  Legacy Boot Options       Disable   / Enable
  TPM Activation Policy     F1 to Boot / Allow user to reject
  MS+Windows UEFI CA 2023   Enable    / Disable

Leading hypothesis: HP Fast Boot reuses CACHED MEMORY-TRAINING DATA rather than retraining each
boot. A DIMM fitted while Fast Boot was on is a plausible route to memory being present,
inventoried, handed to the kernel — and then reserved. It is also the only memory-relevant
setting differing from the working node. NOT TESTED: changing it is a firmware write plus a
reboot and needs operator sanction.

BROADER FINDING for T-7.1: the §1 firmware checklist is now MACHINE-CHECKABLE rather than an
eyeball-at-F10 exercise, and machine-ENFORCEABLE too. That is precisely how node 2 came to have
After Power Loss=Power Off while node 1 has Power On — nobody could see the drift. Follow-up
recorded: extend node_health to assert the firmware checklist, add a role to converge it.

Raw BIOS dumps deliberately NOT committed — they carry serials, UUIDs and MAC addresses, same
reason node-health artifacts are gitignored. Only the findings are recorded.

Serves: R-ENV-03. Task: T-7.1.
2026-09-01 21:04:12 -05:00
jakman85andClaude Opus 5 cb69a53825 feat(prod): enable node 2 + HARDWARE FAULT — it addresses 2.6 GiB of its 16 GB
k3s-prod-2 (192.168.2.11) came online 2026-09-01. Enabled in the inventory, baseline package
floor installed, first health run completed. Vaulted become works on it unchanged.

*** OPEN FAULT: the node can only address ~2.6 GiB of a healthy, correctly-installed 16 GB
DIMM. *** Recorded in PROD-PROVISIONING §0b.

  dmidecode        16 GB Samsung M471A2K43DB1-CTD in DIMM1 @ 2667 MT/s (DIMM3 empty)
  BIOS e820        reports ~16 GiB usable, incl. 0x100000000-0x42f7fffff
  kernel           Memory: 2568544K/16546088K available (13958980K RESERVED)
  last_pfn         revised DOWN 0x42f800 (~16.7 GiB) -> 0xc3c10 (~3.06 GiB) in early boot
  zones            Normal present 3340288 pages (~12.7 GiB) but MANAGED 0
  MemTotal         2,753,284 kB = 2.6 GiB

The DIMM is NOT the problem: it is present, correctly identified, and at rated speed. The
kernel sees all 16 GB and then reserves 13.3 GiB. Everything below ~3 GiB usable, everything
above 4 GiB present-but-unmanaged — the signature of memory remapping above 4 GB not being
applied, not of failing memory. Node 1 is the control: identical chassis, identical BIOS R21
Ver. 02.26.00, identical CPU, and it addresses its full 31 GiB. Per-machine state, not a
firmware-version defect.

WARNING RECORDED: do NOT assume the incoming 32 GB fixes this. If the fault is the slot, the
board or a BIOS setting rather than the DIMM, 32 GB presents identically and the money is
wasted. Verify MemTotal after any RAM change.

ALSO FOUND — the prod nodes are NOT hardware-symmetric:
  node 1  Micron C400 512GB SATA SSD (~2011) — 69% life, 15 grown bad blocks, 187 erase
          failures, 32 unexpected power losses
  node 2  Samsung PM9A1 512GB NVMe        — 96% life, 2142 power-on hours, 34 unexpected
          power losses, overall-health PASSED
Same chassis, same BIOS, same CPU, same partition layout — very different storage. §2 requires
an identical disk layout across all three nodes because Longhorn replica placement assumes
symmetry, so this asymmetry is now a live input to the disk decision rather than a footnote.
Node 2's NVMe is the drive node 1 should have had.

Node 2 otherwise: 0 FAIL / 3 WARN / 12 PASS / 2 SKIP. Same three WARNs as node 1 (swap still
active pending full baseline, single IPv4 resolver, and the NVMe's 34 unexpected power losses),
plus the same unknowable-ECC SKIP.

Serves: R-ENV-01, R-ENV-03, R-OBS-04. Task: T-7.1.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-09-01 20:56:58 -05:00
jakman85andClaude Opus 5 6b4da27f84 feat(prod): SOPS decryption (same age key as dev) + GitOps source on main
gate / gate (push) Has been cancelled
gate / conformance (push) Has been cancelled
Operator decisions, 2026-09-01:
  1. Prod uses the SAME SOPS age key as dev.
  2. Prod tracks the SAME BRANCH as dev (`main`). Dev is a temporary instance and will be
     decommissioned once prod is deemed stable.

SOPS: eight `decryption: {provider: sops, secretRef: sops-age}` patches mirroring dev
exactly — platform, apps-wave-0/1/2, oauth2-proxy, headlamp, crafty, velero. The sops-age
Secret is still created OUT OF BAND on prod (bootstrap/sops/install-age-key.sh); the
overlay references it by name only, never inlines key material.

RECORDED CONSEQUENCE of the shared branch: once prod is live, EVERY MERGE TO main
RECONCILES BOTH CLUSTERS. There is no promotion step and no soak window — dev and prod
move together. That is a deliberate consequence of dev being temporary, not an oversight,
but it removes the "prove it on dev first" safety net that the last few days have leaned
on heavily. Worth revisiting if dev outlives its expected life.

*** BOOTSTRAP BLOCKER recorded, NOT papered over *** — the source URL cannot work on a
cold prod cluster, for two independent reasons found while wiring this:

1. SELF-HOSTING CIRCULARITY. Gitea runs ON THE DEV CLUSTER — the one slated for
   decommission. Prod syncing from it means prod's source of truth lives inside the
   cluster being retired. Gitea must move to prod (or off-cluster) BEFORE dev is torn
   down. This makes Gitea migration the FIRST task of the decommission plan, not the last.

2. SPLIT-HORIZON DNS SENDS IT TO THE WRONG PLACE. platform/coredns/coredns-custom.yaml
   answers the ENTIRE home.keithjackson.dev zone with ${GATEWAY_VIP} via a template
   plugin. On prod that is 192.168.2.20 — PROD's own gateway, where no Gitea listens. Prod
   Flux would resolve gitea.home.keithjackson.dev to itself and never reach a repository.
   This is the same split-horizon mechanism that makes dev work, inverted against us.

Bring-up therefore needs a TEMPORARY source (the bootstrap host-Gitea, or an off-cluster
mirror) with a cutover to the in-cluster URL once Gitea actually runs on prod — precisely
the sequence docs/05 describes for dev's own Phase-6 cutover. The branch is settled and
correct; only the host is blocked. Documented at the patch site and in
PROD-PROVISIONING.md §7.

Gate: MERGE GATE: PASS.

Serves: R-SEC-01, R-GITOPS-01, R-ENV-02, R-ENV-03. Task: T-7.1.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-09-01 16:27:32 -05:00
jakman85andClaude Opus 5 666a60776a fix(flux): close the substitution race — platform dependsOn root + strict substitution (P0/P1)
P0 — clusters/base/platform.yaml gains `dependsOn: [flux-system]`. This is the actual fix
for the incident, not the feature gate. Verified against kustomize-controller v1.4.0
`kustomization_controller.go :: checkDependencies` (our version): dependsOn is REVISION-
gated, not merely Ready-gated — when the dependency shares a GitRepository, the dependent
cannot reconcile revision N until the dependency has APPLIED revision N. Applying revision
N is exactly what writes a newly-added cluster-vars knob.

Graph verified mechanically, not by eye: built clusters/dev and clusters/prod and walked
the resulting objects. `platform` was the ONLY Kustomization without a dependsOn, and all
11 substituting Kustomizations chain transitively through it (platform-config -> platform;
the waves, apps-vms, oauth2-proxy, headlamp, homepage, crafty, velero -> platform-config).
The "not chaining through platform" set is EMPTY, so this one edge protects the whole
graph. DFS over the full edge set after the edit: no cycles. The root (clusters/dev/
sync.yaml) runs wait: false, which is what makes the edge deadlock-free — it reaches Ready
on apply success without health-gating its children.

Accepted trade-off, documented in-file: the root becomes a gate. A malformed manifest
anywhere under clusters/<env> — including clusters/base — now stalls platform and
everything downstream, where today it would not. Fail-closed, per doctrine.

P1 — StrictPostBuildSubstitutions. MY PREMISE WAS WRONG about where this belongs and it
matters: this repo deliberately does NOT use `flux bootstrap` (see bootstrap/flux/README).
There is no gotk-components.yaml in git, and the live kustomize-controller Deployment
carries NO Flux ownership labels — it was installed imperatively by `flux install` from
bootstrap.sh and is not in Flux's inventory. `flux-system` self-manages the CR graph, NOT
the controllers. Nothing under clusters/** can reach a controller flag.

So it uses Flux's documented mechanism for hand-installed clusters: a new
bootstrap/flux/components/kustomization.yaml wrapping `gotk-components.yaml` with a
JSON-6902 patch appending --feature-gates=StrictPostBuildSubstitutions=true to
kustomize-controller. JSON-6902 `add /args/-` deliberately, NOT strategic merge — a
container's args is atomic and a merge patch would replace all five install-generated
args. bootstrap.sh step 1 now renders (`flux install --export` into a temp dir, apply the
patch, ASSERT the gate string is present so a future Flux bump that breaks the patch
target fails loudly) then applies. FLUX_INSTALL_PLAIN=1 is a loud escape hatch. Nothing is
vendored, so components can never drift from the pinned FLUX_VERSION.

Rejected: vendoring gotk-components.yaml under the root's path (the root's prune: true
would put Flux's own controllers and CRDs in a prune inventory), and shipping a partial
Deployment as a Flux-managed resource (a future prune would delete kustomize-controller).

ROLLOUT ORDER MATTERS. P0 arrives automatically on the next reconcile. P1 does NOT arrive
on a git push — the controller Deployment is outside Flux's inventory, so an operator must
re-run bootstrap.sh step 1, which restarts kustomize-controller (~10-20s; Flux is
level-triggered so an interrupted reconcile is simply retried). P0 must be reconciled
BEFORE P1 is rolled out: with the gate on but the ordering edge absent, the same race
turns a transient empty render into a transient hard Kustomization failure.

ALSO FIXES A PHASE-7 BLOCKER THIS CHANGE WOULD OTHERWISE HAVE CREATED. clusters/prod had
no root Kustomization — dev/sync.yaml even carried the note "a prod overlay needs its own
sync.yaml -> ./clusters/prod". With the new dependsOn, a prod bootstrap would have left
platform blocked forever on a flux-system Kustomization that does not exist, and nothing
downstream would ever reconcile. clusters/prod/sync.yaml is now authored, mirroring dev.

Two further prod-overlay gaps found and DOCUMENTED, not guessed (PROD-PROVISIONING §7):
prod has no SOPS `decryption` patch (every encrypted Secret would fail to decrypt — needs
the prod age-key decision, a security choice not a copy), and no GitRepository source URL
patch (needs a decision on whether prod tracks the same branch as dev, which would make a
dev-facing merge reconcile prod).

Substitution gate re-run: check OK, 102 assertions, 0 hazards. Gate: MERGE GATE: PASS.

Serves: R-ENV-02, R-GITOPS-01, R-PLAT-01, R-ENV-03.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-09-01 01:45:04 -05:00
jakman85andClaude Opus 5 fdc4a7d9f4 fix(cilium): maxUnavailable 2 -> 1 — bound CNI rollout blast radius (P2)
During the substitution incident a bad render (k8sServiceHost: "") took down TWO of three
Cilium agents simultaneously. The agents' `config` init container falls back to the API
ClusterIP, which only the Cilium agent itself can translate — and that agent is the one
being replaced — so it deadlocks on `dial tcp 10.43.0.1:443: i/o timeout`.

Root cause of the 2-at-once: `updateStrategy.rollingUpdate.maxUnavailable: 2` is the
UPSTREAM CHART DEFAULT, confirmed by downloading cilium-1.20.1.tgz and reading
values.yaml:437-444 — not a local choice, and not overridden anywhere in this repo.

maxUnavailable: 1 makes a rollout replace ONE agent at a time and stop at the first pod
that fails to become Ready. The whole value of the setting is that the rollout halts on
the first bad node instead of taking the majority of the dataplane with it, and that
guarantee only exists at 1. It matters far more on a cold PROD bootstrap, where there is
no healthy peer to recover from — dev only self-healed because k3s-dev-3 kept a working
agent throughout.

Set as a [parity] field in ALL THREE places, per this repo's documented contract that the
Ansible bootstrap values and the Flux HelmRelease values must agree on settings that
define cluster networking (Ansible installs Cilium at bootstrap; the HelmRelease adopts
it; the two layers fight otherwise):
  platform/cilium/helmrelease.yaml                        (authoritative for Flux)
  infra/ansible/roles/cilium/templates/cilium-values.yaml.j2  (authoritative for bootstrap)
  platform/cilium/values.yaml                             (reference mirror, kept in sync)
Verified by rendering the .j2 with roles/cilium/defaults and diffing full value sets: every
[parity] field is byte-equal across all three; only k8sServiceHost differs, as designed
(${K3S_API_HOST} vs {{ k3s_api_host }}).

MERGING THIS IS NON-DISRUPTIVE. updateStrategy lives at DaemonSet.spec.updateStrategy — a
SIBLING of spec.template (chart daemonset.yaml:49-53). The DaemonSet controller decides a
pod is out of date by hashing spec.template alone, so the pod-template hash does not move,
no new ControllerRevision is created, and zero pods are recreated. Helm patches the field
in place. (If it were disruptive it would be self-defeating: rolling agents under the old
maxUnavailable: 2 in order to install maxUnavailable: 1.) Verify after reconcile with
`kubectl -n kube-system get ds cilium -o jsonpath='{.spec.updateStrategy.rollingUpdate.maxUnavailable}'`
plus unchanged pod ages — that is the cleanest proof nothing rolled.

Trade-off recorded in the comments: upgrades serialise, roughly two waves to three at 3
nodes (a minute or two). On a large cluster this becomes painful and a percentage such as
"10%" would be right — noted so a future larger cluster revisits it deliberately.

SCOPE: this bounds blast radius, it does NOT close the substitution race. A bad render
still ships; it now breaks one node and stalls rather than taking the majority.
platform.dependsOn: [flux-system] (P0) is the fix for the cause.

Serves: R-PLAT-01, R-NET-01.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-09-01 01:40:20 -05:00
jakman85andClaude Opus 5 ff0533106b feat(prod): operator decisions — node DNS, service VIPs, become vault, collections path
gate / gate (push) Has been cancelled
gate / conformance (push) Has been cancelled
1. PROD NODE DNS = 8.8.8.8 + 1.1.1.1 (operator, 2026-09-01). Two INDEPENDENT public
   upstreams, so the single-upstream SPOF that broke containerd pulls and CoreDNS
   forwarding on dev cannot recur. Prod deliberately differs from dev, which is
   PiHole-first because dev needs the local jackson.lan zone.

   SCOPE CORRECTED IN THE COMMENTS. Three resolvers answer *.home.keithjackson.dev and
   only one is configured here:
     pods  -> CoreDNS -> platform/coredns/coredns-custom.yaml, whose `template` plugin
              answers the WHOLE zone with ${GATEWAY_VIP}. Self-contained in-cluster;
              PiHole is NOT in this path. Prod is already correct (.20).
     LAN   -> PiHole. Not a cluster concern.
     nodes -> THIS FILE.
   The one thing public node DNS breaks: the k3s API SERVER is a node process carrying
   oidc-issuer-url=https://keycloak.home.keithjackson.dev/realms/homelab and reaches the
   issuer through the NODE resolver, so prod would get the PUBLIC record instead of the
   prod Gateway VIP — breaking kubectl OIDC SSO. Dev avoids this only because its node
   resolver IS PiHole. Not blocking (prod has no cluster or Keycloak yet); options are
   recorded in PROD-PROVISIONING.md §4 for the operator to pick.

2. SERVICE VIPs DECIDED: UNIFI_L4_VIP 192.168.2.21, CRAFTY_L4_VIP 192.168.2.22 — the
   first two addresses after GATEWAY_VIP (.20), mirroring dev's .53/.54/.55 ordering
   within the .20-.30 pool. S3_BACKUP_ENDPOINT stays TBD-PROD-* : no prod backup target
   exists, and dev's versitygw is across the pfSense boundary on the dev host, so it is
   not DR for prod.

3. PROD BECOME VAULT committed, ansible-vault encrypted, matching the hypervisor and
   proxmox_hosts pattern. Verified working: `ansible k3s_prod -m command -a 'id -un'
   --become` returns root. The L0 no-plaintext-secrets check asserts every ansible
   vault.yml starts with $ANSIBLE_VAULT, so this stays honest by gate.

4. TOOLCHAIN GAP FIXED: the devcontainer image does NOT ship the Galaxy collections, so
   EVERY ansible play died at parse time on community.general.modprobe. ansible.cfg now
   sets collections_path = collections, and the collections are installed there from the
   existing collections/requirements.yml (gitignored — pinned by requirements, fetched at
   setup, vendored bytes are not source).

5. DRIVE HEALTH MEASURED and recorded in §2 with the raw attribute table so the numbers
   are auditable. Verdict: usable, but not for production etcd/Longhorn state — 31% of
   rated life consumed, 15 grown bad blocks, 187 erase failures, and 32 unexpected power
   losses on a consumer drive with NO power-loss protection, in a single failure domain.
   etcd is the worst possible tenant: it fsyncs constantly and unclean power loss without
   PLP is exactly how a member corrupts.

6. NON-ECC RAM: RISK ACCEPTED by the operator, recorded as a CLOSED decision, not an open
   item — do not re-litigate. Rationale: 3-node k3s homelab, not enterprise; corruption on
   one node is outweighed by the other two and causes node ejection. That holds for the
   dominant mode (etcd raft CRC + quorum; Longhorn 3 replicas + hard anti-affinity +
   rebuild). Recorded residual: corruption introduced UPSTREAM of replication replicates
   faithfully to all three replicas, so quorum sees no disagreement — low probability, and
   the only mitigation is different hardware. Follow-up noted: Longhorn's
   snapshotDataIntegrity is left at the chart default rather than set explicitly, and it
   is the mechanism that operationalises the operator's own argument.

Serves: R-DNS-01, R-DNS-03, R-ENV-02, R-ENV-03, R-SEC-01. Task: T-7.1.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-09-01 00:40:29 -05:00
jakman85andClaude Opus 5 0b3db6e778 fix(node_health): SMART verdict was wrong by 4096x — judge on portable signals
The first real SMART run FAILED k3s-prod-1's drive on reallocated=61440. That verdict
was WRONG, and the failure mode is instructive: the check trusted a VENDOR-DEFINED raw
value as if it were an ATA-standard sector count.

Micron TN-FD-20 ("SMART Attributes for the C400 SSD") names attribute 5 "Reallocated
BLOCK Count" and defines its raw as grown-bad-blocks x Block_Sector_Count, where
Block_Sector_Count is 256 x 16 = 4096 for the 128Gb-NAND parts (256GB/512GB). This is
the 512GB C400-MTFDDAC512MAM: 61440 / 4096 = 15. Triply corroborated on the drive itself
— attr 170 Grown_Failing_Block_Ct = 15, attr 196 Reallocated_Event_Count = 15, attr 5
normalised value 100 against thresh 10, and `when_failed` empty on every attribute.
FIFTEEN grown bad blocks, not sixty-one thousand bad sectors.

smartctl(8) states it outright: since ATA/ATAPI-4 rev 4 the meaning of raw Attribute
fields is "entirely vendor-specific". So a raw value can never be a portable verdict.

FAIL now comes only from signals that mean the same thing on every drive: the drive's own
smart_status.passed; NORMALISED value vs the MANUFACTURER's own threshold via smartctl's
when_failed ("now"/"past"/""), split Pre-fail -> FAIL and Old_age-or-past -> WARN; the
ATA-standard counters 197/198/187 (199 CRC is WARN-only — it is link, not media); and for
NVMe critical_warning / media_errors / percentage_used. Wear reads from the NORMALISED
lifetime indicator (202/231/233, or NVMe percentage_used) — a percentage by definition.

Vendor raw counts are still collected and PRINTED WITH THEIR NUMBERS, and may raise a
WARN, but can never drive a FAIL. Attribute 5's raw is now shown beside the normalised
reading that contradicts it, labelled vendor-encoded, with a mechanically-derived
"(= 15 x 4096)". Endurance attributes are matched by THE NAME smartctl's drivedb resolved
for that model, not by bare ID — drivedb is the portability layer; on an unrecognised
drive the name is Unknown_Attribute, nothing matches, and the field stays null with no
claim made. The STORAGE section now prints 170/172/173/174/189/206, whose previous
omission is exactly what let the misread stand unchallenged.

Also documented from TN-FD-20: on this family attr 197 "will always be 0, as reallocation
will be done on-the-fly" — so pending=0 is NOT evidence of health here. The role reports
the number and infers nothing from it.

Branches real hardware cannot exercise were verified with a harness rendering the actual
role expressions against synthetic smartctl payloads: virtio/no-stdout -> SKIP; NVMe
healthy -> PASS; NVMe degraded -> FAIL; a genuinely dying ATA drive (attr 5 normalised 8
<= thresh 10, pending 48) -> FAIL driven by the threshold trip and standard counters, not
the raw; unknown-vendor attrs -> PASS with the unnamed counter ignored; failed-in-the-past
-> WARN.

NEW VERDICTS. k3s-prod-1: 0 FAIL / 4 WARN / 12 PASS / 1 SKIP — SMART is a WARN naming the
real findings (31% of rated life consumed, 15 grown bad blocks, 187 erase failures, 32
unexpected power losses on a drive with no power-loss protection). k3s-dev-1: unchanged,
all three virtio disks still SKIP with their stated reason.

BREAKING (JSON artifact): the fact `reallocated_sectors` is renamed and gone — that name
asserted a unit ATA does not guarantee. Replaced by realloc_attr (the whole attribute,
normalised + raw), realloc_events, and grown_bad_blocks. Nothing in the repo reads it.

Serves: R-ENV-03, R-OBS-04.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-09-01 00:40:29 -05:00
jakman85andClaude Opus 5 c1f24e4a6d fix(dns): resilient node resolvers — mechanism-detecting, per-environment (R-DNS-01/03)
Re-authors the fix stranded on origin/fix/node-dns-resilient-upstream (7a34590). That
commit was NOT landed: it wrote a netplan drop-in and ran `netplan apply`, but netplan
does not exist on these nodes any more (Debian 13 trixie generic cloud image; not in
node_baseline_packages). Landing it would have failed the handler with command-not-found
and BROKEN node-baseline.yml on every node — worse than not landing it. Its dev-LAN
literals also sat in role defaults, which prod inherits, pointing prod nodes at a PiHole
on a network they cannot reach.

The underlying problem is real and verified: a SINGLE upstream resolver is a hard SPOF.
PiHole answers jackson.lan instantly but its external recursion flaps — 0/25 for public
names (registry-1.docker.io, quay.io, ghcr.io) while gitea.jackson.lan resolved 5/5 —
breaking containerd image pulls and CoreDNS `forward . /etc/resolv.conf`.

MECHANISM DETECTION (new `dns` tag in node_baseline). Five read-only probes feed one
set_fact yielding three outcomes, because the two environments no longer share a resolver
stack (dev-1 is behind resolved's 127.0.0.53 stub; prod-1 has a direct resolv.conf and no
cloud-init at all):
  * systemd-resolved — resolved running AND owning /etc/resolv.conf (proven by the
    symlink pointing into /run/systemd/resolve/, or by every nameserver being a resolved
    loopback). Writes resolved.conf.d/99-k3s-dns.conf with an ordered DNS=, Domains=, and
    FallbackDNS= EXPLICITLY EMPTIED so systemd's compiled-in public resolvers can never
    silently bypass the local zone and ad-blocking.
  * resolv-conf-file — plain directly-managed file (prod's shape). Ordered nameserver
    lines + options timeout:2 attempts:2, backup: true. Deliberately NO `rotate`, which
    would destroy PiHole-first ordering.
  * contended — resolvconf/openresolv present or NetworkManager active. Writes NOTHING
    and fails loudly: a change that silently gets reverted is worse than no change.
Resolved-running-but-not-owning-resolv.conf correctly falls through to the file branch.
Ordering is the policy that keeps the local zone working — the second server is only
consulted after the first fails, so a gateway NXDOMAIN can never beat PiHole to a
jackson.lan answer.

SEAMS. Dev values in role defaults ([192.168.1.18, 192.168.1.1], search jackson.lan);
prod values in inventory/group_vars/k3s_prod/vars.yml. NOT cluster-vars — that ConfigMap
is consumed by Flux postBuild for platform/ and apps/, and no Ansible code reads it.

PROD'S SECOND UPSTREAM IS AN OPEN OPERATOR DECISION and is left as a loud
BLOCKED-pending-second-upstream placeholder, the same precedent as the node_baseline disk
devices, with a dns-tagged assert that stops the play before any file is written. A
public resolver was NOT invented as a default: it would bypass the local zone, which is a
decision, not a default. PROD-PROVISIONING.md §4 was rewritten (the old bullet pointed at
the now-dropped branch) to state the choice, including that prod routing to the dev
PiHole is unverified across the pfSense boundary.

tofu: servers = [var.dns_server, var.network_gateway] — the one hunk of the old branch
worth taking as-is. Dev-only by nature.

ALSO FIXES A FALSE WARN THIS WOULD OTHERWISE CREATE: node_health_collect.py parsed
/etc/resolv.conf only, so on dev it read the 127.0.0.53 stub and would report a permanent
single-upstream WARN even after a correct fix. It now asks resolvectl for the real
upstreams when it sees the stub — and if that fails, nameservers is NULL with the reason
recorded, never the stub and never a guess. assess.yml turns null into SKIP, not WARN and
not PASS. The honesty discipline is preserved exactly.

Verified with NO play run against any node: syntax-check + yamllint + tofu fmt clean;
--tags packages still selects ONLY the apt task (the prod package-floor escape hatch
bypasses DNS entirely); --list-hosts unchanged; -c local simulation driving the REAL
detection expression and REAL file bodies extracted from the role by script (so the test
cannot drift) passes all 5 scenarios — dev stub -> systemd-resolved, prod shape ->
resolv-conf-file, NetworkManager and resolvconf -> contended; dev defaults pass the
assert byte-identically while prod overrides fail it by name; collector unit-tested
against 8 resolver shapes.

Serves: R-DNS-01, R-DNS-03, R-ENV-02, R-ENV-03.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-09-01 00:11:49 -05:00
jakman85andClaude Opus 5 e623d27e2d feat(ansible): parameterise target groups so prod reuses the roles unchanged (R-ENV-02)
roles/k3s_server, roles/cilium and every node-host playbook hardcoded the dev group
names k3s_primary/k3s_secondary/k3s_servers, so the prod inventory groups could not be
selected at all. That broke the R-ENV-02 promise that prod reuses the SAME roles, and
blocked PROD-PROVISIONING.md §6 outright.

TWO KNOBS, deliberately separate — Ansible templates a play's `hosts:` BEFORE any host
context exists, so group_vars is unreadable there, while roles run WITH host context:
  * which hosts a play RUNS ON — k3s_hosts, k3s_primary_hosts/k3s_secondary_hosts
    (k3s.yml's split), vpn_egress_gateway_hosts; each `| default(<dev group>)`, set by -e
    only. Follows node-health.yml's established `<name>_hosts | default(dev)` pattern.
  * which group a ROLE means by "my primary"/"my servers" — k3s_primary_group,
    k3s_servers_group in group_vars/all.yml (dev), overridden in group_vars/k3s_prod.
    Follows the k3s_api_host convention already in this repo. No per-run flag.

DEV IS UNCHANGED — the key evidence. --list-hosts/--list-tasks/--syntax-check captured
for all 9 playbooks at HEAD and after: sorted host lists IDENTICAL for all 9, same
primary/secondary split, same 6-play site.yml. (Raw --list-hosts PRINT ORDER varies run
to run; proven to be Ansible's own set ordering by running UNMODIFIED HEAD cilium.yml
four times -> 3,1,2 / 1,3,2 / 1,2,3 / 1,2,3. Hence sorted comparison.) --list-tasks
differs in exactly two files, only by added TAGS annotations and one new assert; no task
reordered, renamed or removed. Var resolution verified per environment with -c local:
dev -> k3s_primary/192.168.1.50/sans .50,.49,127.0.0.1,.51,.52; prod ->
k3s_prod_primary/192.168.2.10/vip .9/sans .10,.9,127.0.0.1,.11,.12.

BREAKS THE SMARTMONTOOLS CIRCULAR DEPENDENCY. node_baseline tasks are now tagged
packages/system/disks, so the package install can run alone:
  ansible-playbook playbooks/node-baseline.yml -e k3s_hosts=k3s_prod --tags packages
Skipping is the guard — no disks-tagged task is selected, so the
BLOCKED-pending-disk-decision paths are never templated, let alone passed to mkfs.
Belt-and-braces, a new disks-tagged assert fires first in a FULL run and names §2
explicitly instead of failing obscurely at mkfs. `tags: never` was deliberately NOT used
(it would change the default run).

FOOTGUN FOUND AND FIXED: roles/cilium, cluster_verify and flux_bootstrap all hardcoded
.cache/dev.kubeconfig — the exact file infra/devcontainer/dev.sh exports as $KUBECONFIG.
Once prod became targetable, a prod cilium/verify run would have SILENTLY OVERWRITTEN it,
leaving the operator's kubectl quietly answering from PROD. Now cluster_kubeconfig_name
(dev.kubeconfig -> prod.kubeconfig). Dev path byte-identical.

KNOWN, DOCUMENTED, NOT FIXED HERE: flux-bootstrap.yml retargets but roles/flux_bootstrap
shells out to bootstrap/flux/bootstrap.sh with a hardcoded --path=clusters/dev — a
bootstrap/ subtree change, not a target-group change (§6, cross-referenced to §7).
vpn.egress.gateway.yml is parameterised but prod has no egress group yet and would need
its own vaulted PIA credentials. --check against prod is still impossible until the prod
vault exists — even the packages-only run needs it.

Nothing was run against the dev cluster: --list-hosts/--list-tasks/--syntax-check, plus
debug/assert with -c local, only.

Serves: R-ENV-01, R-ENV-02, R-ENV-03. Task: T-7.1.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-08-31 23:53:36 -05:00
jakman85andClaude Opus 5 9f59c36000 feat(ansible): node_health role — read-only hardware health for prod + dev nodes
Operator ask: implement the roles needed to check prod node hardware health, and run
them to find out our state. This is that role; the run's findings are below.

roles/node_health is a read-only sibling to cluster_verify (cluster health vs hardware
health), styled after node_baseline. One unprivileged collector script does the work in
a single SSH round trip — reading /sys/class/dmi, thermal + hwmon, EDAC, cpufreq +
thermal_throttle, /proc/pressure, /sys/block incl. SCSI ioerr/iotmo counters, lsblk,
lscpu, mounts + statvfs, per-NIC stats, resolv.conf.

THE DESIGN POINT: an unreadable field is emitted as null WITH A RECORDED REASON, never
as zero. The summary ends with a "NOT READ (and why) — these are UNKNOWNS, not passes"
section. A fake zero on a reallocated-sector count is exactly the kind of false green
this project refuses. 22 checks report PASS/WARN/FAIL/SKIP/INFO; every SKIP says why.
Report-only by default; thresholds live in defaults/main.yml.

Portable across bare metal AND VMs — validated against k3s-prod-1 (bare metal, no root)
and k3s-dev-1 (VM, root). VM-absent things (SMART on virtio, coretemp, EDAC) skip
cleanly, and iSCSI/Longhorn volumes are split out of the physical-disk set so a live
replica is never mistaken for a spare device.

playbooks/node-health.yml takes its target group as a variable (-e node_health_hosts=
k3s_prod), deliberately unlike the other playbooks that hardcode k3s_servers — see the
group-name gap already flagged in hosts.ini.

Two become facts found the hard way and documented in the role: a group_vars
`ansible_become: true` OUTRANKS `become: false` as a play/task keyword, so unprivileged
tasks must override the variable; and `failed_when: false` does NOT catch "Missing sudo
password" — only `ignore_errors` does.

FIRST RUN, k3s-prod-1, 2026-08-31: 0 FAIL · 3 WARN · 12 PASS · 3 SKIP · 4 INFO.
Box is healthy, cool and unstressed: i7-9700T 8C/8T, VT-x + /dev/kvm (KubeVirt OK), zero
throttle events, hottest sensor 33C, PSI 0.00 across the board, 31.1 GiB RAM, eno1 up at
1000 Mb/s, BIOS R21 02.26.00, no reboot pending.

DRIVE HEALTH IS STILL UNKNOWN — the headline. SMART did not run, blocked TWICE over: no
vaulted ansible_become_password for prod, AND smartmontools is not on the node at all
(node_baseline has never run there). Power-on hours, wear, reallocated/pending sectors
and drive temperature all remain unmeasured on a ~2011 consumer SSD.

WARNs: kernel ioerr_cnt=6 on sda (read cautiously — four freshly attached iSCSI disks on
dev each showed a flat 7, suggesting a fixed per-device discovery cost, not media
trouble; attribution needs dmesg/root); 0.95 GiB swap still active (node_baseline does
the swapoff); one IPv4 resolver only (the other two upstreams are IPv6 Google), which
refines rather than resolves the DNS-SPOF finding.

ESCALATION — ECC status is UNKNOWABLE on this hardware: /sys/devices/system/edac/mc
exists but no controller is bound. Non-ECC consumer RAM. Silent memory corruption on a
prod node would be undetectable. Recorded as a SKIP with reason, not a pass.

Serves: R-ENV-01, R-ENV-03, R-OBS-04. Task: T-7.1.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-08-31 23:20:25 -05:00
jakman85andClaude Opus 5 a1fb31a7ef docs(prod): record the decided prod address plan; packages-in-role correction
PROD-PROVISIONING.md §4 now carries the full operator-decided address table (nodes
.10/.11/.12, control-plane VIP .9, ingress Gateway VIP .20, Cilium LB pool .20-.30) with
the two invariants that make it safe: the control-plane VIP sits outside the LB pool so
kube-vip and LB-IPAM cannot contend, and GATEWAY_VIP is the FIRST address of the pool
because the shared Gateway pins nothing and LB-IPAM hands it the first free address.

§5 no longer tells the operator to hand-install smartmontools — package installation is
the node_baseline role's job (operator ruling). §0 gains the node 2/3 addresses.

Task: T-7.1. Gate: MERGE GATE: PASS.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-08-31 22:44:10 -05:00
jakman85andClaude Opus 5 666cc0d809 feat(ansible): prod node inventory + vaulted become; smartmontools into node_baseline
Prod inventory scaffolding for the three bare-metal nodes, and the become posture the
operator ruled for production.

BECOME: prod does NOT get dev's NOPASSWD sudo. Prod keeps a real sudo boundary and
supplies the password to Ansible as an ansible-vault-encrypted `ansible_become_password`
in inventory/group_vars/k3s_prod/vault.yml, mirroring the existing hypervisor and
proxmox_hosts groups. The decrypting passphrase stays outside the repo
(~/.config/home-k3s/ansible-vault-pass), so plays still run unattended with no plaintext
secret in git. Committed here: README.md + vault.yml.example only — the operator creates
the encrypted vault (`ansible-vault create`), as with every other vaulted group.

PACKAGES BELONG IN THE ROLE (operator ruling): smartmontools is now declared in
node_baseline_packages, not hand-installed on a node. Drive health tooling is a
permanent part of a bare-metal node's baseline — dev nodes are VMs and never needed it.
Same click-ops-never principle as the rest of the repo.

ADDRESSING: nodes .10/.11/.12, reached DIRECTLY on the LAN (no pfSense NAT hop, unlike
dev's 192.168.2.102:225x mapping), so ansible_host is the real node IP. kube-vip
control-plane VIP is 192.168.2.9 — deliberately BELOW the nodes and OUTSIDE the Cilium
LB pool (.20-.30) so kube-vip and LB-IPAM can never contend for an address. The ingress
Gateway VIP (.20) and the LB pool are Flux/cluster-vars concerns and deliberately do
not appear in Ansible.

BLOCKED-BY-DESIGN: node_baseline_longhorn_device / node_baseline_etcd_device are present
but set to an obviously invalid /dev/BLOCKED-... path pending the operator's disk-layout
decision (node 1 is a single SATA SSD; the role's /dev/vdb,/dev/vdc defaults are virtio
names that do not exist on bare metal). Leaving them unset would silently fall back to
those equally-nonexistent defaults — a confusing failure that looks like a wiring bug.
This fails just as hard and says exactly why.

KNOWN FOLLOW-UP: roles/k3s_server and every node-host playbook hardcode the literal
group names k3s_primary/k3s_secondary/k3s_servers, so the k3s_prod_* groups are not
selected by them as-is. Harmless now (nothing can accidentally run against prod) but the
"same roles, unchanged" reuse R-ENV-02 promises needs the target group parameterized
before §6 of PROD-PROVISIONING.md can execute. Documented in hosts.ini and both READMEs.

Serves: R-ENV-01, R-ENV-03, R-SEC-01. Task: T-7.1. Gate: MERGE GATE: PASS.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-08-31 22:44:10 -05:00
jakman85andClaude Opus 5 e3c44368c8 docs(prod): correct sudo posture to vaulted become; record status-surface ruling
Two operator corrections:

1. PROD DOES NOT GET NOPASSWD SUDO. My initial checklist recommended mirroring dev's
   passwordless sudo onto prod — rejected, correctly. Dev's NOPASSWD is a convenience
   that must not propagate to production. Prod instead keeps a real sudo boundary and
   drives Ansible `become` with an ansible-vault-encrypted `ansible_become_password` in
   inventory/group_vars/k3s_prod/vault.yml, mirroring the EXISTING hypervisor and
   proxmox_hosts groups. The decrypting passphrase stays outside the repo at
   ~/.config/home-k3s/ansible-vault-pass (ansible.cfg :: vault_password_file), so plays
   still run unattended with no plaintext secret in git.

2. THE TASK BOARD IS NOT THE STATUS SURFACE — THE REPOSITORY IS. Operator ruling closes
   the escalation raised in the previous commit. Requirement/spec status is to be DERIVED
   from repo state (what is authored, reconciled, and covered by a green requirement-tagged
   test), not from a hand-maintained board. The spec board is left as a historical seed;
   no agent edits it and no SPEC_PIN churn is spent on it. ci/spec-immutability.sh keeps
   its full strictness — no path exception was added, since weakening an R-TEST-06 gate
   for a bookkeeping file would be a defect, not a fix. A repo-derived spec status report
   becomes the artifact of record alongside the coverage report and this log.

Serves: R-ENV-03 (prod provisioning posture), R-SEC-01 (no plaintext secrets), R-TEST-06.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-08-31 22:29:39 -05:00
jakman85andClaude Opus 5 574088dfeb 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]>
2026-08-31 22:17:51 -05:00
jakman85andClaude Opus 4.8 c182888133 docs: PM handoff — 2026-08-31 current-state, gotchas + next steps; PHASE1-STATUS 8 vCPU
Appends the definitive current-state/handoff entry to DECISIONS-LOG (SSO fixed via CVE-2025-30162
egress allow, 5 forward-auth UIs gated, 8 vCPU, Gitea Actions CI live, external-snapshotter vendored;
operational gotchas; prioritized Next Steps → Longhorn-SSD, L2/L3-CI, forward-auth long-term,
Phase-6 onboarding). Updates the reconnect guide (6→8 vCPU) and points new agents at the handoff.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-31 21:23:04 -05:00
jakman85andClaude Opus 4.8 676c37a247 tofu: node vCPU 6 -> 8 (CPU spike headroom)
Steady-state CPU PSI 15-23% + 15-min load 5.6-8.0 on 6 cores (run queue at/over core count) left no
headroom for bursty workloads. Proxmox host has 24 cores at ~4% load, so 3x8 = 24 vCPU is 1:1 with
zero oversubscription. In-place tofu update (cores change is pending until a per-node VM stop/start);
rolled one node at a time to keep etcd quorum. Comment also corrected 16->24 GiB (stale).

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 23:47:49 -05:00
jakman85andClaude Opus 4.8 1f921fbfed docs(ansible): add re-provision runbook + node-host playbook list
A node rebuild (tofu -replace / fresh OS) wipes host-level config Flux/Helm don't manage.
site.yml omits kube-vip.yml and vpn.egress.gateway.yml, so a re-provision missed the node-host
OpenVPN on k3s-dev-3 and dropped all egress-class=vpn pod traffic. Document the node-host layers
that must be re-run after any re-provision, and correct the stale author-only banner (these plays
are live).

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 21:18:29 -05:00
jakman85andClaude Opus 4.8 22db5fdb63 kyverno: 3.3/v1.13 -> 3.9/v1.19 (stay-current) + CLI lockstep
- HR chart 3.3.x -> 3.9.x (Kyverno v1.13.6 -> v1.19.0).
- crds.install:false + CRDs pre-applied server-side (5.7 MB bundle exceeds kubectl's 256 KB
  annotation limit; Helm client-side apply would stall the platform Kustomization, kps-style).
- CLI lockstep (ci/conformance/devcontainer versions.env + run-l0.sh default) -> 1.19.0.
  Pre-verified: v1.19.0 kyverno CLI passes the L0 suite 17/17 with the existing test format.
- Policies are kyverno.io/v1 ClusterPolicy (stable API, unchanged in v1.19).

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 16:28:16 -05:00
jakman85andClaude Opus 4.8 cbc2301b30 docs: reconcile docs/comments with post-upgrade cluster state
Text-only cleanup after the upgrade campaign. Updates stale version
strings, prose, and comments to the verified current facts; no
Kubernetes behavior or version pins changed except the kubectl
toolchain bump (below).

Verified facts applied: k3s v1.36.4+k3s1, Debian 13 trixie,
Cilium 1.20.1 / Gateway API v1.6.1, Longhorn 1.12.1, node RAM 24 GiB,
dedicated virtio2 SSD etcd disk per node, Velero chart 12.x / v1.18,
Grafana 13.2.0.

- Version strings across infra/ and platform/ READMEs + comments
- kubectl toolchain 1.31.4 -> 1.36.4 (devcontainer/ci/conformance
  versions.env; 1.31 vs a 1.36 cluster exceeded the +-1 skew)
- Retired-single-apps-Kustomization refs -> apps-wave-0/1/2 + apps-vms
  with per-wave SOPS decryption (flux/clusters docs + bootstrap.sh)
- COMPLETED/historical banners on the three executed plan docs
- Resolved TODO(WS-SEC) markers -> Renovate-maintained ranges
- Appended dated DECISIONS-LOG entry (2026-08-30) superseding the
  2026-08-26 LIVE STATE line

Left as revalidation items (not blind-edited): external-snapshotter
v8.2.0 vs 1.36, Cilium ext_authz/forward-auth relevance under 1.20.1,
conformance ImageVolume feature-gate assertions under 1.36.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 15:13:12 -05:00
jakman85andClaude Opus 4.8 dbd73f1f88 kube-vip: v0.8.9 -> v1.2.3 (k8s 1.36 catch-up)
Manifest env-var config (manager/cp_enable/svc_enable/vip_arp/leaderelection) is unchanged across
0.8->1.2, so the bump is image + re-applied auto-deploy manifest.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 14:58:33 -05:00
jakman85andClaude Opus 4.8 d84feac736 OS upgrade complete: Debian 12->13 (trixie) baseline + re-provision role fixes
All 3 k3s nodes re-provisioned to Debian 13 (kernel 6.12) via immutable tofu -replace,
one at a time, leader/primary last. variables.tf image defaults -> trixie generic.
k3s_server role: ensure /etc/rancher/k3s exists (fresh-node re-provision fix).

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 11:09:57 -05:00
jakman85andClaude Opus 4.8 ef0a735145 node_baseline: add cryptsetup (Longhorn 1.12 RequiredPackages) for Debian 13 re-provision
Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 10:12:53 -05:00
jakman85andClaude Opus 4.8 7a59ef07bb Upgrade complete: pin k3s_version v1.31.5 -> v1.36.4+k3s1
Cluster upgraded 1.31.5 -> 1.36.4 over 5 sequential minor hops (binary-swap per node,
leader-last, Longhorn rebuild-freeze). Components: Cilium 1.16.5->1.20.1, Longhorn
1.7.3->1.12.1, GW-API CRDs ->v1.6.1, etcd 3.5->3.6. All validated; data intact.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 02:17:17 -05:00
jakman85andClaude Opus 4.8 b4b3bb0922 W5 (FINAL): Cilium 1.19.7->1.20.1 (+GW-API CRDs v1.6.1), Longhorn 1.11->1.12.1 (pre-k8s-1.36)
Cilium 1.20 is mandatory for k8s 1.36. GW-API CRDs v1.4.1->v1.6.1 (direct, never v1.5.x).

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 00:22:53 -05:00
jakman85andClaude Opus 4.8 36173b9529 W3: Cilium 1.18.13->1.19.7 (+GW-API CRDs v1.4.1), Longhorn 1.9->1.10.2 (pre-k8s-1.34)
Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-30 00:00:23 -05:00
jakman85andClaude Opus 4.8 cd8cf6220b W2: Cilium 1.17.18->1.18.13 (+GW-API CRDs v1.3.0), Longhorn 1.8->1.9 (pre-k8s-1.33)
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]>
2026-08-29 23:46:09 -05:00
jakman85andClaude Opus 4.8 5efd983239 W1: Cilium 1.16.5->1.17.18, Longhorn 1.7->1.8 (pre-k8s-1.32 component landing)
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]>
2026-08-29 23:23:34 -05:00
jakman85andClaude Opus 4.8 af5fc5b25f feat(tofu,ansible): SSD-backed etcd disk per k3s node (Phase 1: code + plan)
Interim bridge to stop Longhorn replica-rebuild I/O storms on the shared HDD
Storage pool from starving etcd WAL fsync (crash-looping k3s / flapping the
kube-vip VIP). Adds a small dedicated SSD disk per node for etcd only; Longhorn
stays on HDD. See docs/plans/ssd-etcd-isolation.md.

tofu (infra/tofu):
- New vars etcd_ssd_datastore (default "local-zfs" = rpool/data, Micron 5100
  SATA SSD mirror w/ PLP) and etcd_disk_gib (default 16).
- New virtio2 disk block on the SSD datastore per VM: discard=on, cache=none
  (honor guest fsync straight to the ZFS ZIL — safe on PLP SSD), iothread=false.
  Kept last (ascending interface) so bpg does not reorder virtio0/virtio1.
- Revert the debian_cloud_image resource to the long type name
  proxmox_virtual_environment_download_file to match the R2 state: bpg >= 0.111
  dropped the cross-type moved{} linkage to the short proxmox_download_file, so
  the stale moved block failed EVERY plan with "Resource type mismatch" (broken
  on main too). Aligning code to state yields a clean plan with no image
  re-download. Short-name migration is deferred to a deliberate `tofu state mv`.

ansible (node_baseline):
- Format /dev/vdc (label k3s-etcd) and mount it at
  /var/lib/rancher/k3s/server/db (defaults,noatime; no nofail so a missing etcd
  disk fails loudly rather than silently landing etcd on the root HDD) before
  k3s starts, so a rebuilt node comes up with etcd isolated on SSD. Data-safe:
  filesystem module never reformats an existing fs.

Phase 1 only: non-disruptive. No tofu apply, no node/VM/etcd/Longhorn changes.
tofu plan verified: 0 to add, 3 to change, 0 to destroy — every VM an in-place
disk ADD (virtio2), dev-3 also an in-place memory 16384->24576; no VM replace.
Merge gate green (render==golden included).

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-29 17:21:06 -05:00
jakman85andClaude Opus 4.8 a60d34a4c3 tofu: bump k3s node memory_mib default 16384 -> 24576 (24 GiB)
Raise per-node RAM from 16 GiB to 24 GiB for proper failover headroom.
Matches the live rolling resize of the three k3s-dev VMs on Proxmox
(qm set --memory 24576 per node, one at a time, KSM enabled first).

Single memory_mib var applies to all three nodes via for_each, so a
future `tofu apply` would resize all three at once and break etcd
quorum — the resize MUST be done live/rolling, not via apply.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-29 12:55:45 -05:00
jakman85andClaude Opus 4.8 6739339f53 Replace MinIO backup target with versitygw (s3_backup_target role)
MinIO's open-source edition is de-prioritised (console removed, commercial
pivot), so swap the off-cluster S3 backup target on the Proxmox host to
versitygw v1.7.0 (github.com/versity/versitygw) — a maintained Go S3 gateway
serving a POSIX filesystem as S3.

Rename role minio_backup_target -> s3_backup_target and playbook backup-minio
-> backup-s3. The role now:
  - decommissions any pre-existing MinIO (service/binary/env/mc-client/user/
    object-layout), KEEPING the ZFS dataset Storage/k3s-backups and its mount
  - installs the pinned, checksummed versitygw binary (fetched+extracted on the
    controller, host has no internet), a dedicated versitygw system user, and a
    Type=simple hardened systemd unit running the posix backend rooted at
    /mnt/Storage/k3s-backups/data, bound to 192.168.1.9:9000 (same endpoint),
    plain HTTP / path-style
  - ensures the dataset has xattr=sa (versitygw stores object metadata in xattrs)
  - pre-creates the velero + cnpg buckets (bucket == top-level subdir)

Credentials are REUSED: versitygw's ROOT key is set to the same scoped
access_key/secret the cluster already uses, so endpoint + key + secret + bucket
names are byte-identical to the old MinIO target. The GitOps SOPS secret
(platform/backup/minio-credentials.sops.yaml) and all cluster-side Velero/CNPG
config need ZERO change. The vaulted group_vars now expose
s3_backup_target_access_key/_secret_key (same values, MinIO root creds retired).

Verified live on the Proxmox host: versitygw active+enabled on 192.168.1.9:9000,
MinIO fully removed, dataset intact; SigV4 ListBuckets with the reused key
returns velero+cnpg; a throwaway in-cluster pod reaches http://192.168.1.9:9000
(versitygw S3 response). Re-run is idempotent (no host changes).

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-28 22:48:38 -05:00
jakman85andClaude Opus 4.8 ac32f01f7b feat(backup): MinIO S3 backup target on Proxmox host for Velero + CNPG
Stand up a single-node/single-drive MinIO S3 endpoint on the Proxmox host as the
off-cluster backup target for Velero (R-STATE-03) and CloudNativePG (R-IDP-05).

Ansible (author + executed):
- roles/minio_backup_target + playbooks/backup-minio.yml — idempotent, additive only:
  ZFS dataset Storage/k3s-backups (zstd, quota=100G, /mnt/Storage/k3s-backups, no
  sharenfs); minio system user; pinned+checksummed MinIO/mc binaries (fetched on the
  controller since the host has no WAN, copied to host); hardened systemd unit bound to
  the host's cluster-reachable LAN IP (auto-discovered) on :9000; velero + cnpg buckets;
  a non-root access key scoped by IAM policy to only those two buckets.
- inventory: new [proxmox_hosts] group ([email protected].2.102); overrides the cluster-wide
  ansible_user. Does not disturb existing k3s node entries.
- group_vars/proxmox_hosts/vault.yml (ansible-vault): root + scoped MinIO creds.

GitOps hand-off:
- platform/backup/minio-credentials.sops.yaml (+ .example) — SOPS/age-encrypted endpoint +
  scoped key/secret for the Velero/CNPG wiring (WS-STORAGE/WS-SEC). Not yet wired into a
  kustomization (left for the consuming agents).

Verified live: dataset props correct; minio active+enabled bound to 192.168.1.9:9000;
S3 endpoint http://192.168.1.9:9000/minio/health/ready returns 200 from an in-cluster pod;
buckets velero+cnpg present; scoped key created+policy attached; re-run is idempotent.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-28 22:15:05 -05:00
jakman85andClaude Opus 4.8 0cf0c669f4 tofu: migrate to non-deprecated proxmox_download_file (ADR-007)
bpg/proxmox deprecates proxmox_virtual_environment_download_file ("Use
proxmox_download_file instead. This resource will be removed in v1.0."),
the short-name rename from ADR-007. Both are the same dual-registered
Framework resource, so rename the resource type + import_from reference
and add a `moved` block. OpenTofu 1.9 drives the provider's MoveState
(migration.PrefixMoveState) to transfer state in place: same id, no
re-download of the Debian image, no change to the VMs.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-28 11:22:06 -05:00
jakman85 7d93decd61 tofu: fill encrypted secrets 2026-08-27 19:53:46 -05:00
jakman85andClaude Opus 4.8 216bea2a16 tofu: move secrets into committed SOPS/age file + tf.sh wrapper
Replace the gitignored plaintext infra/tofu/.r2.env and backend.hcl with a
single committed, SOPS/age-encrypted dotenv (secrets.sops.env) plus a thin
wrapper (tf.sh), so tofu runs with no manual secret entry and secrets live
encrypted in git like the repo's other secrets.

- .sops.yaml: creation rule encrypting infra/tofu/secrets.sops.env (all values)
  to the existing age recipient.
- secrets.sops.env: encrypted, PLACEHOLDER values only. Holds R2 S3 keys, the
  state-encryption passphrase (TF_STATE_PASSPHRASE scalar), and the Proxmox API
  token/endpoint. Operator fills real values via `sops`.
- tf.sh: sops exec-env decrypts the dotenv, exports PROXMOX_VE_*/AWS_*, builds
  the multi-line TF_ENCRYPTION HCL from TF_STATE_PASSPHRASE, and runs tofu
  (injecting -backend-config=backend.r2.hcl on init). Proxmox token stays env-only,
  never a tofu variable/state.
- backend.r2.hcl: committed non-secret R2 bucket/key/endpoint (account id is not
  a credential), passed to `tofu init`.
- Retire .r2.env/backend.hcl(.example): drop the committed templates; keep the
  gitignore lines as a safety net for leftover local plaintext.
- Update backend.tf/README/REMOTE-STATE for the new day-2 flow and DR story
  (repo + age key is sufficient).

Verified: placeholder file round-trips sops -e/-d with the repo age key; tf.sh
exports the expected VAR NAMES and builds valid TF_ENCRYPTION HCL (stub tofu, no
real plan/secrets).

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-27 19:07:52 -05:00
jakman85andClaude Opus 4.8 df947b33d0 infra(tofu): fix backend.tf HCL header + document encryption-adoption migration
backend.tf began with a stray YAML `---` doc separator (invalid HCL) that broke
`tofu` parsing. Remove it. Also document the one-time `unencrypted` fallback method
needed to adopt encryption on pre-existing plaintext state (add for the migrate,
remove after), so the record is complete. State migration to R2 verified: 4/4
resources read back through the encrypt-only method (proves ciphertext at rest).

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-27 16:31:23 -05:00
jakman85andClaude Opus 4.8 485b9e3888 infra(tofu): scaffold off-cluster R2 remote state (encrypted)
Local-only tfstate meant losing the workstation would strand a rebuild (apply
would try to recreate the 3 live nodes). Move state to Cloudflare R2, which sits
OUTSIDE the Proxmox->VM->cluster->Gitea chain, so a full cluster rebuild can still
read it; encrypted at rest via OpenTofu native AES-GCM.

Adds a partial s3 backend (R2 skip-flags), gitignored backend.hcl/.r2.env for the
account-specific + secret bits, their .example templates, and a migration+DR runbook.
Locking (use_lockfile) deferred to an OpenTofu >=1.10 bump (1.9.0 lacks it).
Migration (tofu init -migrate-state) runs once the operator provisions the R2 bucket.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-27 15:57:12 -05:00
jakman85andClaude Opus 5 f7d3884ad2 fix(ci): scope the requirement matcher to the diff and to non-doc files
`ci/touched-requirements.sh` documents its detection as "R-* tokens literally
present in the diff of changed files". It did not do that — it grepped the ENTIRE
CONTENT of every changed file. So a change inherited every requirement those files
had ever mentioned in prose, and `--require-all` then blocked the merge on
requirements the author never went near.

On this branch that meant editing the decision log and the tofu docs dragged in
five unrelated requirements, all on untouched lines, all legitimately uncovered:

  [coverage] REQUIRE: FAILED — required requirement(s) uncovered: [5 IDs]

The practical effect was that the PM could not append to the decision log without
failing CI — which is a fair part of why the log went stale in the first place.
This is the defect already logged as "FOLLOW-UP (WS-TEST): fix the matcher so real
requirements need not be exempted".

Two scoping rules, both learned from the gate blocking merges it should not have:

  1. Scan the ADDED/REMOVED lines of the diff, as the header always claimed.
     Removed lines count too — deleting a test's requirement tag, or a policy's
     self-declared ID, touches that requirement just as much as adding one.

  2. Skip `*.md`. An ID in prose is a REFERENCE, not a declaration: explaining a
     requirement is not changing behaviour against it. Rule 1 alone is not enough —
     a commit that documents a mis-attribution names the IDs involved and thereby
     re-triggers the very mis-attribution it fixes, and the decision log can never
     record which requirements a change concerned.

This TIGHTENS attribution rather than weakening the gate:
  - no requirement is exempted, and DOCUMENTED_GAPS is untouched;
  - authoritative declarations (`conformance.home.k3s/R-*` tags, Kyverno policies,
    ServiceDefinitions) all live in YAML, on lines a real change must touch;
  - the coarse path->requirement fallback is unchanged and file-type agnostic, so
    the doc subtrees that matter (conformance/, schemas/, catalog/, clusters/, ci/)
    stay covered either way.

Alternatives rejected: adding the five IDs to DOCUMENTED_GAPS genuinely weakens the
gate; scrubbing requirement IDs out of prose (precedent f9e9640) would mean editing
the decision log's own history to appease a matcher.

Gate semantics change — flagged in DECISIONS-LOG.md for review.

Also drops three R-TEST-06 mentions this branch had added to prose and refreshes
the now-stale "gate is RED" notes.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-08-27 00:06:28 -05:00
jakman85andClaude Opus 5 12c40d8c9c docs: reconcile the documentation with the deployed reality
The docs had drifted badly behind ~85 commits of delivery. The root README still
said "Phase 0 — Foundations. No cluster exists yet"; the infra docs still
described a libvirt/KVM cluster that has been retired for two days; and
DECISIONS-LOG.md — the PM's authoritative record — stopped at 2026-08-25 AM.
Anyone following these docs would have been working from a false map.

Verified against the live cluster (3/3 nodes, 7/7 Flux Kustomizations Ready,
10/10 HelmReleases Ready) rather than inferred from commit messages.

README.md
  - Phase 0 -> a per-phase status table: 0-6 delivered and deployed, 7 not open.
  - Layout now shows the wave split, platform-config, apps/vms, infra, bootstrap.
  - Real conformance number (36/51, 70.6%) and how to regenerate it.
  - Devcontainer workflow; note that the gate was red and why.

infra/PHASE1-STATUS.md — rewritten. Was a `virsh`/libvirt resume guide for a
  cluster that no longer exists. Now: the Proxmox substrate, the pfSense NAT
  paths, both kubectl access paths (Keycloak OIDC normal / cert break-glass),
  the toolchain, off-repo state that must not be lost, and the fact that Flux's
  git source is an app inside the cluster (`git push origin main` IS the deploy).

infra/PHASE1-SCOPE.md — historical banner. The exit criteria and sizing
  rationale are still worth keeping; the libvirt execution steps are not.

infra/README.md — Proxmox, plus a map of the subtree and where the cluster
  actually lives (it is not on this workstation).

infra/devcontainer/README.md — the "run tofu and ansible on the HOST" limitation
  is OBSOLETE: it was a dmacvicar/libvirt polkit/PID problem, and bpg/proxmox
  talks to an HTTP API. Everything runs in the container now. Documents the full
  CI-gate toolchain and what each bind mount is load-bearing for (the age keyring
  and the read-only spec repo especially — without the latter, spec-immutability
  silently skips instead of verifying).

infra/tofu/README.md — was "Authoring only — nothing here has been applied". It
  is applied and live. Disk sizes corrected 40/100 -> 64/128 GiB (confirmed
  against the running nodes), pfSense NAT marked done, and a warning that
  terraform.tfstate is absent on a fresh workstation — an apply with empty state
  would try to recreate the three live nodes.

infra/tofu/variables.tf — section comment disagreed with its own defaults.

infra/cluster.sh — retired-with-instructions header. It silently drives libvirt
  domains that do not exist; behaviour unchanged, but it no longer lies.

apps/vms/unifi/README.md — was "NOT WIRED IN", 60Gi, and listed a file that has
  since been dropped. Now: live status, 40Gi, resolved open questions marked
  resolved, and the two constraints the next person will otherwise rediscover —
  KubeVirt's 2048B inline userData cap, and that apps-vms must never carry
  postBuild.substituteFrom (envsubst corrupts the cloud-init).

DECISIONS-LOG.md — backfilled the gap as one structured entry: the Proxmox
  migration, NAT + kube-vip, the twice-proven oauth2-proxy cold-start deadlock,
  the Flux source cutover, CI going live in-cluster, ten app onboardings and the
  renderer bugs they exposed, the wave split (verified: DBs adopted, not
  recreated — original ages intact, prune restored), KubeVirt storage, the UniFi
  VM, and kubectl SSO. Plus verified live state and the carried-forward open list.

Two corrections to the record while verifying:
  - kubectl OIDC is LIVE (`kubectl auth whoami` -> oidc:<user>,
    [oidc:platform-admins]), so the rolling restart 3472f1d deferred has
    happened.
  - UniFi OS Server is NOT installed in the guest. The VM is healthy (Ubuntu
    24.04.4, guest agent connected, live-migratable) but :11443 answers nothing,
    and the CNP explicitly permits cluster -> :11443, so it is genuinely not
    listening rather than a policy artifact.

Docs and comments only; no manifest semantics change.

Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
2026-08-27 00:00:05 -05:00
jakman85andClaude Opus 4.8 3472f1d161 feat(auth): Keycloak OIDC login + RBAC for kubectl (cert kubeconfig stays break-glass)
Lets users kubectl into the cluster via Keycloak SSO, mapping realm groups to
cluster RBAC. The cert-based admin kubeconfig is untouched and remains a fully
independent break-glass path (works even if Keycloak/OIDC is down).

- keycloak-realm-import.yaml: new `kubernetes` PUBLIC client + PKCE (S256) — no
  client secret in any kubeconfig; kubelogin runs auth-code+PKCE to localhost.
  groups mapper + email/profile/roles scopes.
- k8s-oidc-rbac.yaml (NEW, platform-config): ClusterRoleBindings
  oidc:platform-admins -> cluster-admin, oidc:viewers -> view.
- k3s_server role: kube-apiserver-arg OIDC flags (issuer=homelab realm,
  client-id=kubernetes, username-claim=email + oidc: prefix, groups-claim=groups
  + oidc: prefix). No oidc-ca-file (nodes reach the issuer via the gateway VIP
  and trust the public LE cert). Applied via the rolling Restart k3s handler.

Keycloak/RBAC land via Flux now; the API-server flags take effect on the next
`ansible-playbook playbooks/k3s.yml` rolling restart (deferred until cluster load
from the VM-import incident settles).

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-26 17:37:05 -05:00
jakman85andClaude Opus 4.8 d8101bca38 chore(ansible): set private_key_file for k3s node connectivity
The k3s nodes authorize ~/.ssh/home_network for the `k3s` user, but ansible.cfg
set no private_key_file and there's no ssh_config entry for the SSH-NAT host, so
node-config plays (e.g. the rolling k3s config.yaml + Restart handler) failed
with Permission denied (publickey). Pin the key so those plays connect without a
per-run --private-key.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-26 15:27:29 -05:00
jakman85andClaude Opus 4.8 df5979fceb fix(k3s): enable nonroot-devices so CDI can import to Block-mode PVCs
The UniFi VM boot-disk DataVolume (RWX + Block on longhorn-vm) failed to import:
CDI's non-root importer (UID 107, cap-drop ALL) hit
`blockdev: cannot open /dev/cdi-block-volume: Permission denied`.

Kubernetes only applies fsGroup ownership to *filesystem* volumes — it never
chowns a raw block device — and Longhorn's CSIDriver (fsGroupPolicy:
ReadWriteOnceWithFSType) skips fsGroup on RWX/Block volumes regardless, so the
device stays root:root. The CDI-documented fix is the container-runtime setting
`device_ownership_from_security_context`, exposed on k3s (>= v1.31.3+k3s1, this
cluster is v1.31.5) as `nonroot-devices: true`. It makes containerd set the
in-container device node's owner from the pod's securityContext.

Added to the Ansible-managed /etc/rancher/k3s/config.yaml alongside tls-san;
applied via the existing rolling `Restart k3s` handler (serial:1, kube-vip keeps
the API up, etcd holds 2/3). Node-scoped, security-neutral (pods stay non-root),
and preserves the longhorn-vm RWX/Block/migratable contract unchanged.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-26 15:24:07 -05:00
jakman85andClaude Opus 4.8 81ef78295a infra: direct kube-API access via kube-vip VIP + NAT (retire SSH tunnel)
Controller now reaches the kube-API directly through the pfSense NAT
(192.168.2.50:6443 -> kube-vip VIP 192.168.1.49:6443), validating TLS
against the VIP via tls-server-name. Removes the dev.sh SSH-tunnel
scaffolding and updates the ansible source-of-truth so a rebuild
regenerates a direct-access kubeconfig.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-25 22:10:27 -05:00
jakman85andClaude Opus 4.8 60a58f01ad feat(infra): kube-vip control-plane HA VIP (192.168.1.49) + API tls-san
Add an HA control-plane API VIP for the k3s cluster with kube-vip, and add
the VIP + all node IPs to the kube-apiserver serving-cert SANs so TLS via the
VIP validates. Prepares the stable failover endpoint the operator fronts with
a pfSense port-forward to 192.168.1.49:6443.

roles/kube_vip + playbooks/kube-vip.yml:
- Templates a single manifest (RBAC + DaemonSet kube-vip-ds) into each server's
  k3s auto-deploy dir (/var/lib/rancher/k3s/server/manifests) so it is
  reproducible and independent of Flux; k3s auto-applies it.
- Control-plane ONLY (cp_enable=true, svc_enable=false): Cilium keeps ownership
  of Service LoadBalancing (L2 pool .53-.60) — no ARP conflict.
- Runs on control-plane nodes (nodeSelector node-role.kubernetes.io/control-plane),
  hostNetwork, NET_ADMIN/NET_RAW, image pinned ghcr.io/kube-vip/kube-vip:v0.8.9.
- vip_interface auto-detected per node (the iface holding 192.168.1.5x = eth0).
- Leader election (plndr-cp-lock) with 15/10/2s lease timings.
- This cluster runs without kube-proxy (Cilium replacement), so a hostNetwork
  pod cannot reach the kubernetes ClusterIP; kube-vip is pointed at the
  node-local apiserver (KUBERNETES_SERVICE_HOST=127.0.0.1:6443) so leader
  election works.

roles/k3s_server tls-san:
- New k3s_tls_sans (VIP + all three node IPs + 127.0.0.1, deduped); install
  args now emit one --tls-san per entry.
- Persist the SAN list to /etc/rancher/k3s/config.yaml (read by a running k3s)
  and Restart k3s handler so an existing cluster regenerates its serving cert.
- k3s.yml secondaries run serial:1 so a SAN change rolls one node at a time,
  keeping etcd quorum (kube-vip keeps the API reachable during each restart).

Verified live: DS 3/3 ready, VIP answers on 192.168.1.49:6443, all 3 certs and
an s_client against the VIP carry 192.168.1.49 + .50/.51/.52 + 127.0.0.1, all
nodes Ready throughout the rolling restart.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-25 21:52:43 -05:00
jakman85andClaude Opus 4.8 bb48f675ee ci: bake pinned test toolchain into devcontainer + fix conformance layer/spec-immutability seams
Bake the conformance harness toolchain into infra/devcontainer so `make -C ci gate`
runs identically here and in CI:
- Containerfile: install kyverno CLI (1.13.4), kyverno-json, chainsaw (0.2.12),
  yamllint (1.35.1), check-jsonschema (0.29.4), yq (4.44.6) via new pinned RUN block;
  add diffutils + python3-pip; drop stale LIBVIRT_DEFAULT_URI; refresh header for the
  Proxmox(bpg)+conformance toolbox; extend /etc/dev-toolchain-versions provenance.
- versions.env: add KYVERNO/KYVERNO_JSON/CHAINSAW/YAMLLINT/YQ/CHECK_JSONSCHEMA;
  align KUBECTL 1.32.0 -> 1.31.4. dev.sh build(): pass the new --build-args.
- ci/versions.env: pin CHECK_JSONSCHEMA_VERSION=0.29.4 (single source of truth).

Fix harness seams so the gate can run:
- dev.sh run(): mount the sibling spec repo (home-network-k3s) read-only at
  /home-network-k3s for ci/spec-immutability.sh (R-TEST-06); conditional so the
  container still runs without it.
- conformance/lib/common.sh conf_dirs_for_layer(): accept a comma/space list of
  layers and union the dirs, so ci/conformance.sh `run.sh --layer l2,l3` selects
  both layers in one pass (backward compatible for single layers).

NOTE: ci/versions.env pins KYVERNO_JSON_VERSION=0.0.5, which has no upstream release
(max tag is v0.0.3; platform/kyverno/scripts/run-l0.sh already defaults to v0.0.3).
Baked v0.0.3 and flagged for PM to correct ci/versions.env. kyverno-json is not used
by any static gate stage.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-25 15:43:19 -05:00
jakman85andClaude Opus 4.8 0d7495486e devcontainer: wire dev.sh to the Proxmox k3s cluster
- drop stale libvirt socket mount + LIBVIRT_DEFAULT_URI (old KVM cluster)
- auto-open an SSH tunnel (local :16443 -> primary 127.0.0.1:6443 over the
  pfSense SSH NAT) on each run so kubectl/flux/helm reach the cluster with no
  manual setup; DEV_NO_TUNNEL=1 opts out, K3S_SSH_* env overrides the NAT front
- refresh header/usage comments (bpg/proxmox, not dmacvicar/libvirt)

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-25 14:59:19 -05:00