Autonomous prod bring-up, operator away. Three changes that together clear the last
blockers before `flux bootstrap`.
=== 1. TEMPORARY BOOTSTRAP GITEA — the last hard blocker, cleared ===
clusters/prod's source URL could not work: Gitea runs ON the dev cluster (the one slated for
decommission) and split-horizon DNS resolves gitea.home.keithjackson.dev to PROD's OWN
gateway. Stood up the existing bootstrap/gitea/bootstrap-gitea.sh on the operator's
workstation with HOST_NAT_IP=192.168.2.132; all three prod nodes verified reachable
(Gitea 1.22.6 via the API), no firewall change needed — prod is on the same /24, no NAT.
clusters/prod now points at http://192.168.2.132:3000/... under a boxed TEMPORARY banner
with a 5-step cutover checklist ending 'delete this whole block — dev's stanza is what done
looks like'. Repo verified PUBLIC with anonymous read two independent ways (API
"private":false; git ls-remote unauthenticated with GIT_TERMINAL_PROMPT=0), so NO secretRef
is needed — documented so a future auth failure is not misread as a network fault.
bootstrap-gitea.sh's header corrected: it documented HOST_NAT_IP=10.73.0.1, the RETIRED
libvirt NAT, and forbade agent use; the operator has now directed this for prod.
=== 2. WIRELESS DISABLED ON PROD (operator-reported) ===
k3s-prod-3 was on ethernet AND wireless, and the wifi DHCP client was overwriting
/etc/resolv.conf. Root cause of the silence: node_baseline's DNS `contended` detection
checked resolvconf and NetworkManager but NOT dhcpcd, so the role wrote resolvers, reported
success, and dhcpcd reverted them on lease renewal — the exact 'green run that fixed
nothing' the contended branch exists to prevent.
Now IaC, not a one-off: survey wireless hardware, **REFUSE to disable it if the path to the
node runs over the wireless interface** (the guard that meant an agent dying mid-apply cost
nothing), blacklist the driver so it never reloads, stop dhcpcd only where it holds a
wireless interface and nothing else, take links down and unload modules with NO reboot, then
report the resulting state. dhcpcd is now in the contended set without weakening fail-closed.
Applied and verified: node 3's wlp1s0 is GONE from /sys/class/net, dhcpcd inactive and its
unit not-found, ONE default route per node, all three on 8.8.8.8/1.1.1.1 resolving public
names. Safe and idempotent on nodes 1 and 2, whose wifi hardware was already down.
=== 3. flux_bootstrap PATH PARAMETERISED ===
bootstrap/flux/bootstrap.sh already read FLUX_ENV_PATH but the role never exported it, so it
ALWAYS bootstrapped clusters/dev — prod was impossible. Two behaviour-bearing lines: role
default clusters/dev + `environment: FLUX_ENV_PATH`, overridden to clusters/prod in
group_vars/k3s_prod. Proven per host with a read-only Ansible probe: prod hosts resolve
clusters/prod, localhost/hypervisor resolves clusters/dev. Only two definitions repo-wide.
DEV PROVEN BYTE-IDENTICAL for the source change: all 12 substituting Flux paths rendered for
both trees, 27/27 SHA-256 artefacts identical, with TWO POSITIVE CONTROLS (an overlay-level
canary and a deep-path content canary) confirming the harness detects change — and both
canaries proven restored. Honest scope note recorded: kustomize strips comments, so the
harness proves the built stream, not source comments.
L0 substitution check: 106 assertions, 0 hazards. ci/l0.sh and ci/lint.sh exit 0.
=== STILL BLOCKING A FULL PROD RECONCILE (operator decisions) ===
- S3_BACKUP_ENDPOINT remains TBD-PROD-*: prod CANNOT reach dev's versitygw at
192.168.1.9:9000 (verified UNREACHABLE from all three — the pfSense boundary), and a prod
backup target is a deferred operator decision. Deliberately NOT invented: a DR target on a
workstation container would create false confidence. Velero/CNPG backups will fail loudly.
- Prod's public resolvers mean the API server's oidc-issuer-url resolves PUBLICLY, so kubectl
SSO will not work on prod until split-horizon is solved for it (§4).
- The temp Gitea is a single container on the operator's workstation — a single point of
failure for prod reconciliation, acceptable for bring-up only.
Serves: R-GITOPS-01, R-DNS-01, R-DNS-03, R-ENV-02, R-ENV-03. Task: T-7.1.
Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
Prod is being stood up now, without waiting for node 2's RAM upgrade. Three coupled
changes, all applied and verified on all three nodes.
=== 1. KERNEL >= 6.13 — now a PREREQUISITE, not a nice-to-have ===
A k3s SERVER that intermittently boots with 2.6 GiB is not a degraded node; it fails under
etcd plus its workload share, unpredictably, on any reboot. Fixed before k3s goes on.
roles/node_baseline gains a `kernel`-tagged block: asserts the suite matches the node's
Debian release, writes a deb822 trixie-backports source, installs, reads back the exact
version, writes a provenance/rollback note to the node. Scoped by
node_baseline_backports_kernel (default FALSE, true only in group_vars/k3s_prod) — chosen
over a hostname test so a fourth prod node inherits it from group membership. Verified:
--check against dev skips all 8 tasks on all 3 hosts. Two deliberate calls: `state: latest`
not `present` (linux-image-amd64 was already installed from main, so `present` would have
silently fixed nothing), and NO preferences.d pin (backports' NotAutomatic +
ButAutomaticUpgrades already gives 100/500; an explicit Pin-Priority: 100 would switch OFF
automatic security upgrades for the very kernel being installed).
Installed 7.1.8+deb13-amd64 on all three; 6.12.107 kept bootable.
THE DECISIVE PROOF: node 2 booted at MEMATTR=0xbeeb0018 — the EXACT address that gave it
2.6 GiB twice — and now reserves 634,904K instead of 13,958,980K. MemTotal 15.4 GiB. Same
address, handled correctly; not a lucky draw.
§0b's claim that a fixed kernel prints 'FW_BUG Corrupted...' is CONDITIONAL and was
corrected: >=6.13 has three rejection gates and only the third prints that line; all three
nodes hit gate 1 (version > 2). Proof instead is boot-independent — decompressing
/boot/vmlinuz on all three yields the FW_BUG and descriptor-size strings verbatim; neither
exists in 6.12.
TWO MORE BUGS IN MY OWN HEALTH CHECK, found because the fix couldn't otherwise be shown:
- MEMATTR_VERSION_RE matched (\d+) but the kernel prints that field with %d — SIGNED. Node
2's real value was -1569980416, which did not match, so state fell through to `clean` and
the node reported PASS "the kernel accepted it without complaint". A FALSE PASS on the
exact bug the check exists to find. Now (-?\d+).
- bad_version was WARN unconditionally, so a FIXED node would have stayed WARN forever.
Now keys on memattr_kernel_fixed: same line, WARN below 6.13, PASS at/above.
=== 2. DISK LAYOUT — Longhorn claimed, per-node paths DISCOVERED not hardcoded ===
Operator decision: reuse the ~424 GB partition; accept the shared-device I/O risk (dev's
etcd/Longhorn contention was on a spinning HDD, prod is SSD/NVMe).
Device paths differ per node (sda5 / nvme0n1p5 / sda5), so the role DISCOVERS the partition
via `findmnt --mountpoint` on a declared claim mountpoint rather than trusting inventory.
Per-host host_vars would have frozen today's hardware into inventory, where it goes stale on
the first re-image and the stale value's failure mode is mkfs on the WRONG partition.
Eleven fail-closed asserts before any write: real block device, not backing / /boot /usr
/var /home /tmp or active swap (built from the node's OWN gathered facts, never a hardcoded
list), already ext4, no foreign label, >= 100 GiB, and empty. Relabel, never reformat.
/srv verified empty first on every node (ls -A -> lost+found only; du 20K; the "5.1% used"
was ext4's default 5% root reserve).
=== 3. k3s DATA-DIR MOVED — /var was 11.8 GiB and would have killed etcd ===
Measured on the fully-deployed dev cluster: containerd 21-25 GB/node, /var total 58-70 GB.
Prod's /var is 11.8 GiB and held BOTH etcd and the image store, so prod would have filled
/var during its first image pulls — and a full /var means etcd cannot write its WAL. Cluster
death, not degradation, arriving during bring-up. Invisible when the disk decision was made,
because "etcd on root" sounded like the 30 GiB / rather than a separate 12 GiB /var.
Now: p5 -> /data (LABEL=k3s-data), with /data/longhorn and /data/k3s. Neutral names chosen
deliberately — the partition now has two tenants, and reusing /srv would make "claimed" and
"unclaimed" indistinguishable to the idempotency pivot, while a bare `data` label would make
a stranger's `data` volume look already-claimed and weaken an assert.
The transition off the existing LABEL=longhorn mount is DECLARED, not inferred
(node_baseline_data_retired_fs_label/_retired_mount, defaults ""), because changing the label
makes a claimed node answer "no" to the pivot and walk into the greenfield path. Self-retiring
once blkid -L k3s-data succeeds. THREE independent gates keep live dev out: retired vars
default ""; gated on longhorn_source == claim-mountpoint (dev is `device`); and the emptiness
assert fails closed on dev's 18 volumes even if both were defeated.
k3s_data_dir is one variable read by two roles (k3s_server --data-dir; node_baseline derives
the etcd mount). Role default is k3s's own default, so dev is unchanged and keeps its
dedicated etcd device. node_baseline_etcd_source becomes `shared-data-partition` and is
LOAD-BEARING: the role asserts per run that the filesystem backing the etcd dir really IS the
data partition — had the mount silently failed, etcd plus 21-25 GB of images would land back
on the OS filesystem invisibly until the disk filled.
LONGHORN_DATA_PATH is a new cluster-vars knob (R-ENV-02): base and DEV /var/lib/longhorn,
prod /data/longhorn.
DEV PROVEN UNCHANGED, which is the property that mattered — the live cluster has 18 Longhorn
volumes on that path. All 12 substituting Flux paths rendered through
`kubectl kustomize | flux envsubst --strict` for both trees: 12/12 per-file SHA-256 identical
and an identical aggregate SHA over every rendered dev byte. With a POSITIVE CONTROL showing
the same harness detects prod changing on exactly one line — an all-identical result is
worthless if the harness cannot see change. Live check after: dev's default-data-path setting
still /var/lib/longhorn, 18 volumes attached, 0 Kustomizations unready.
Idempotent: run 2 is changed=0 on all three nodes. Also fixed a real tag bug — include_tasks
does NOT propagate its own tags to included tasks (unlike import_tasks), so `--tags disks`
selected the include and ran nothing inside it while reporting success.
OPEN DEFECTS, tracked not forgotten: node 2's warm-reboot hang (one clean reboot since, NOT a
fix); and node 3 runs dhcpcd for its wifi interface, which rewrites /etc/resolv.conf on lease
renewal — the role's `contended` detection checks resolvconf and NetworkManager only, so node
3's decided resolvers will silently revert.
Gate: MERGE GATE: PASS. L0 substitution check 106 assertions.
Serves: R-ENV-01, R-ENV-02, R-ENV-03, R-STATE-01, R-STATE-02, R-PLAT-01. Task: T-7.1.
Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
Closes the transition opened in merge 1 (63f98aa). `prune: true` is restored on the
`platform` Kustomization now that the ownership transfer is VERIFIED on the live cluster,
not merely expected:
13/13 Kustomizations Ready, `cilium` among them, at main@sha1:23aa2854
Namespace/kube-system label kustomize.toolkit.fluxcd.io/name = cilium
HelmRelease/cilium label ... = cilium
HelmRepository/cilium label ... = cilium
platform inventory: 0 entries matching kube-system__Namespace | kube-system_cilium_*
cilium inventory: exactly those three objects
Cilium pods UNCHANGED from the pre-merge baseline —
cilium-2f8h8 r=0 2026-09-01T05:55:27Z
cilium-425m8 r=1 2026-08-30T13:25:10Z
cilium-54cww r=0 2026-09-01T05:55:26Z
HelmRelease still v11
So the relabel deterministically preceded any prune, exactly as the revision-gated
dependsOn edge predicted, and the ownership move cost zero pod restarts.
The in-file comment now records the lesson rather than the temporary state: before moving
ANY platform/* component in future, check whether it is the sole declarer of a shared
Namespace. platform/cilium/namespace.yaml was the only declaration of Namespace/kube-system
under ./platform, which would have turned a component-scoped prune into
`delete namespace kube-system` — taking coredns, metrics-server, local-path and Cilium.
L0 substitution gate: 103 assertions, 0 hazards.
Serves: R-PLAT-01, R-GITOPS-01.
Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
Cilium was one of ~12 components inside a single `platform` Kustomization with wait:true,
so the CNI's health was indistinguishable from eleven unrelated components in the tier's
Ready condition, and the only emergency valve was freezing the whole platform tier. This
repo already set the precedent in reverse (oauth2-proxy and headlamp were split OUT so
unhealthy leaves would not gate a tier); Cilium is the mirror image — the one component
that legitimately SHOULD gate everything.
New clusters/base/cilium.yaml: path ./platform/cilium, wait:true, prune:true, interval 1h
(a CNI does not need a 10m re-render cadence; kustomize-controller is source-triggered so
a push still reconciles immediately — the interval is only the drift-correction floor),
timeout 10m (a 3-node DaemonSet rollout with wait exceeds the 5m default),
dependsOn:[flux-system], and postBuild.substituteFrom: cluster-vars — the last is
LOAD-BEARING, not decorative: helmrelease.yaml references ${K3S_API_HOST} and
kustomize-controller now runs --feature-gates=StrictPostBuildSubstitutions=true, so
without it this Kustomization would fail immediately.
*** THE HAZARD WAS FAR WORSE THAN "the CNI gets pruned" ***
platform/cilium/namespace.yaml is the ONLY declaration of Namespace/kube-system anywhere
under ./platform, and the live object carries kustomize.toolkit.fluxcd.io/name=platform.
With prune:true, the moment ./platform/cilium leaves platform's path the stale set is not
"the Cilium HelmRelease" — it is `kubectl delete namespace kube-system`, taking coredns,
metrics-server, local-path AND Cilium. A full cluster kill, not a CNI kill.
TWO INDEPENDENT PROTECTIONS, deliberately not trusting either alone:
1. prune:false on `platform` for this transition merge — Flux's documented Procedure 1 for
moving resources between Kustomizations. Chosen over the per-resource
`kustomize.toolkit.fluxcd.io/prune: disabled` annotation because that needs THREE merges
and leaves the new Kustomization owning resources it can never prune.
2. The pruner's own owner-label filter. In v1.4.0, prune() passes Inclusions:
GetOwnerLabels(obj.Name...), so platform only deletes objects whose LIVE labels still
say name=platform. The new cilium Kustomization relabels all three to name=cilium on
apply, and platform.dependsOn:[cilium] is REVISION-GATED, so platform provably cannot
reconcile revision N until cilium has APPLIED revision N. The relabel deterministically
precedes the prune.
Protection 2 alone would probably have sufficed. Not betting kube-system on "probably".
NOTED FOR THE FUTURE, in-file: anyone moving a platform/* component must first check
whether it is the sole declarer of a shared Namespace — that turns a component-scoped
prune into a cluster-scoped one.
Verified: `kubectl kustomize platform` goes 88 -> 85 documents, 3 removed / 0 added /
0 CHANGED, and `kubectl kustomize platform/cilium` reproduces those 3 byte-identical
(sha256-matched). A pure ownership move; no Cilium value touched. L0 substitution gate
103 assertions (was 102), new cilium row, 0 hazards. Server-side dry-run against the live
cluster accepted both CRs. clusters/prod renders clean off the same base.
MERGE 2 (restore prune:true) follows only after verifying: 13/13 Ready; kube-system, the
HelmRelease and the HelmRepository all relabelled to name=cilium; platform's inventory no
longer lists them; and Cilium pod ages/restarts UNCHANGED from
cilium-2f8h8 r=0 2026-09-01T05:55:27Z / cilium-425m8 r=1 2026-08-30T13:25:10Z /
cilium-54cww r=0 2026-09-01T05:55:26Z, HelmRelease v11.
Serves: R-PLAT-01, R-GITOPS-01.
Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
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]>
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]>
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]>
R-ENV-02 promises dev and prod differ ONLY by scoped cluster-vars overrides. In fact
dev LAN addresses were hardcoded into base manifests, so clusters/prod would have come
up ANNOUNCING DEV ADDRESSES (192.168.1.x) on the prod LAN (192.168.2.x).
New cluster-vars knobs (base default = dev literal, per the file's existing convention):
K3S_API_HOST platform/cilium/helmrelease.yaml (+ the values.yaml mirror)
CILIUM_LB_POOL_START platform-config/cilium/l2-ip-pool.yaml
CILIUM_LB_POOL_STOP "
UNIFI_L4_VIP apps/vms/unifi/50-service-l4.yaml
CRAFTY_L4_VIP platform/crafty/service-l4.yaml
S3_BACKUP_ENDPOINT platform/keycloak/postgres-cluster.yaml, apps/wave-0/{nextcloud,
semaphore}-db.yaml, and platform/velero/helmrelease.yaml
Also fixes GATEWAY_VIP's base default, which was still the RETIRED libvirt address
10.73.0.240, and adds the GATEWAY_VIP patch that clusters/prod was missing entirely.
clusters/base/apps-vms.yaml gains postBuild.substituteFrom (it was the one consuming
Kustomization without it, so a ${TOKEN} there would have shipped as a literal string).
The envsubst contract is documented there: ${VAR} substitutes and escapes as $${VAR};
$VAR and $(cmd) are left alone; ${ARR[0]} hard-errors. The three UOS_URL expansions in
the unifi cloud-init are escaped accordingly.
PROD ADDRESS PLAN (operator, 2026-08-31):
nodes .10/.11/.12 · control-plane VIP .9 (Ansible-side) · GATEWAY_VIP .20
Cilium LB pool .20-.30
CONTAINMENT INVARIANT, now documented at the pool and in the prod overlay: GATEWAY_VIP
MUST equal CILIUM_LB_POOL_START. The shared Gateway pins no address, so Cilium LB-IPAM
gives it the first free address of a matching pool block. An initial prod proposal put
.20 outside a .21-.30 pool; the Gateway would have come up on .21 while split-horizon
coredns-custom kept answering *.home.keithjackson.dev with .20 — an address nothing
announces — blackholing in-cluster OIDC hairpin traffic while reporting healthy. The
pool was widened to .20-.30. The control-plane VIP (.9) stays outside the pool so
kube-vip and LB-IPAM can never contend.
Values prod still cannot know stay INVALID `TBD-PROD-*` placeholders on purpose: base
defaults are dev values, so an omitted patch means prod silently inherits a dev address
— far worse than a loud failed apply.
DEV IS BYTE-IDENTICAL. Verified by kustomize build over 13 paths before/after, then
flux envsubst with the dev cluster-vars values applied to both sides: zero drift. The
only deltas are the intended additive keys in the overlay ConfigMap itself. No
unresolved ${TOKEN} survives. render-golden green (10 goldens); yamllint clean.
Serves: R-ENV-02. Task: T-7.1 (prerequisite). Gate: MERGE GATE: PASS.
Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
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]>
Add Crafty Controller 4 (registry.gitlab.com/crafty-controller/crafty-4:4.10.8)
as a platform component: a web panel that runs Java + Bedrock Minecraft servers as
subprocesses in one pod + a 20Gi Longhorn PVC (mounted 5x by subPath).
Auth = Option B (per-app oauth2-proxy reverse-proxy sidecar), since Cilium 1.16.5
cannot do ext_authz on the shared Gateway:
- oauth2-proxy v7.8.1 sidecar (:4180) reverse-proxies to Crafty's self-signed HTTPS
UI (127.0.0.1:8443), gated to Keycloak homelab realm group platform-admins.
- Confidential `crafty` client provisioned live via kcadm + captured in the realm
import; client secret + cookie secret via SOPS/age (mirrored in realm-clients).
- Web UI: HTTPRoute crafty.home.keithjackson.dev -> Service :80 -> sidecar :4180.
- Game ports: Cilium L2 LoadBalancer on VIP 192.168.1.55 (next free after .53/.54),
starter set TCP 25565-25567 (Java) + UDP 19132-19134 (Bedrock), NOT auth-gated.
- fsGroup:0 / runAsGroup:0 / runAsUser:1000 for the image's crafty:root identity on
the root:root Longhorn PVC (the seerr fsGroup lesson).
- Own non-gating Flux tier clusters/base/crafty.yaml (dependsOn platform-config,
wait:false) + sops-decryption patch in clusters/dev — a leaf UI must never gate
the platform.
- Explicit default-deny NetworkPolicy + CiliumNetworkPolicies (platform namespace,
not app-namespace, so Kyverno does not auto-generate the baseline).
make -C ci gate green; kustomize build of platform/crafty, clusters/base,
clusters/dev clean.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
The 7 falsely-firing platform alerts (KeycloakDown, KeycloakDatabaseDown,
KubeAPIDown, KubeletDown, VPNTunnelDown, KubeVirtControlPlaneDown,
CDINoDefaultStorageClass) share ONE root cause, not per-rule label mismatches:
the Prometheus PVC is 100% full ("no space left on device" on every WAL commit).
Evidence from the live dev cluster:
- /prometheus is 4.8G/5Gi, 0 bytes free; every scrape logs "Scrape commit
failed ... write to WAL: no space left on device". Scrapes still return 200
(targets show healthy, lastScrape=now) but samples are never stored, so the
TSDB head froze at 2026-08-28 13:45 UTC while the pod clock reads ~19:33 UTC.
- Instant queries at "now" therefore return an EMPTY vector, so every
absent()/==0 platform rule trips. Evaluated at the last-good-sample time each
expr is correctly FALSE (keycloak-0/keycloak-db-1 ready=1, apiserver+kubelet
up=1 x3, tun0 series present, kubevirt control-plane expr empty, CDI default
present) — the rules are correct; the monitor was simply blind.
`retention` alone prunes only by AGE: this cluster is 3d2h old with 3d dev
retention, so time-pruning has NEVER run and 3d of block churn (~1.2Gi/day) plus
a WAL that ballooned past 1Gi overran the 5Gi disk. Fix adds a size-based
retention cap (new MONITORING_PROMETHEUS_RETENTION_SIZE knob) kept below each
env's PVC so Prometheus drops oldest blocks before the disk fills, and bumps the
dev PVC 5Gi->8Gi for real WAL/head/compaction headroom.
- platform/monitoring/kube-prometheus-stack.yaml: retentionSize: ${knob}
- clusters/base/cluster-vars.yaml: knob default 8GiB (base 10Gi PVC)
- clusters/dev/kustomization.yaml: PVC 5Gi->8Gi, retentionSize 5GiB
- clusters/prod/kustomization.yaml: retentionSize 45GiB (50Gi PVC)
- platform/monitoring/README.md: knob table + rationale
Deploy note (PM): the PVC is already 100% full, so Prometheus cannot self-prune
until it can write. The 5Gi->8Gi bump must land as a Longhorn online expansion
(operator PVC expansion / manual patch); once free space returns, retentionSize
keeps it healthy. Watchdog left untouched.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
Deploy Homepage (gethomepage) as the apex landing dashboard aggregating
links to cluster services, in its OWN non-gating post-platform Flux
Kustomization (clusters/base/homepage.yaml, dependsOn platform-config,
wait:false) — mirrors headlamp/oauth2-proxy so a leaf UI can never gate
the platform chain.
- platform/homepage/: plain manifests (ns, config ConfigMap, Deployment,
Service, default-deny+Cilium ingress NP, apex HTTPRoute). Non-root pod,
HOMEPAGE_ALLOWED_HOSTS, bundled mdi-* icons (DNS-only egress).
- gateway.yaml: add https-apex + http-apex-redirect listeners for the bare
apex (the *.home wildcard listener does NOT match it). Apex is already a
SAN on the wildcard cert — no new Certificate.
- Forward-auth annotated (auth-mode=forward-auth) but NOT enforced: the
Gateway ext-authz mechanism is an unbuilt Phase-6 WS-NET TODO (same status
as all other forward-auth apps). Flagged as PM follow-up.
Gate: lint/l0/render-golden(10/10)/l1 green; conformance skipped (no cluster).
Co-Authored-By: Claude Opus 4.8 <[email protected]>
Headlamp's HelmRelease sat in the wait:true `platform` Flux tier. Its pod
crashlooped (`flag provided but not defined: -session-ttl` — chart 0.40.1
renders a container arg the appVersion v0.40.1 backend lacks; upstream
kubernetes-sigs/headlamp#4883), and because it gated `platform`, the whole
chain stalled: platform Ready=Unknown -> platform-config, oauth2-proxy,
apps-wave-0/1/2 and apps-vms all Ready=False "dependency not ready".
Part A (unblock + durable lesson): a leaf UI must never gate the chain. Move
all Headlamp resources into a new non-gating Flux Kustomization
clusters/base/headlamp.yaml (dependsOn platform-config, wait:false, SOPS
decryption patched per-env in clusters/dev) — mirroring oauth2-proxy exactly.
The new Kustomization owns the whole platform/headlamp component; its HTTPRoute
moves from platform-config into platform/headlamp/kustomization.yaml. Removed
headlamp from platform/kustomization.yaml and its httproute from
platform-config/kustomization.yaml. Now a crashlooping Headlamp can never stall
platform/platform-config/apps.
Part B (make it start): pin the chart to 0.41.0 (`>=0.41.0 <0.42.0`). The
backend added `f.Int("session-ttl", …)` in v0.41.0 and chart 0.41.0 pins that
same image (appVersion == chart version), so chart+image realign; every arg the
chart renders for our values is supported. OIDC config + per-user RBAC
(clusterRoleBinding.create:false) unchanged.
Gate: `make -C ci gate` PASS.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
oauth2-proxy is a leaf forward-auth service that depends on Keycloak +
trusted wildcard TLS + split-horizon DNS. It lived in the gating `platform`
Flux Kustomization (wait:true), so on a cold start it Failed until those
dependencies existed, keeping the whole `platform` tier not-Ready. That in
turn blocked `platform-config` — which brings up the very Keycloak instance,
wildcard Certificate and L2 VIP oauth2-proxy needs (and previously carried
oauth2-proxy's own httproute/servicemonitor) — from ever reconciling. A
self-gating cold-start deadlock, twice-proven (DECISIONS-LOG sessions 7 & 9).
Break the cycle by moving the whole oauth2-proxy component out of the
`platform` tier into its own non-gating post-platform Flux Kustomization:
- clusters/base/oauth2-proxy.yaml: new Kustomization -> ./platform/oauth2-proxy,
dependsOn platform-config, wait:false, substituteFrom cluster-vars.
- clusters/base/kustomization.yaml: reference the new Kustomization.
- platform/kustomization.yaml: drop the oauth2-proxy component (no longer in
the gating tier).
- platform/oauth2-proxy/kustomization.yaml: pull in httproute + servicemonitor
so the full component travels together.
- platform-config/kustomization.yaml: drop the in-place oauth2-proxy
httproute/servicemonitor refs (moved with the controller).
- clusters/dev/kustomization.yaml: add the SOPS decryption patch for the new
oauth2-proxy Kustomization (it now owns the encrypted credentials Secret that
the `platform` Kustomization used to decrypt).
Now `platform` reaches Ready without oauth2-proxy; platform-config brings up
Keycloak/TLS/DNS; then oauth2-proxy reconciles against dependencies that
already exist. wait:false guarantees its health can never gate anything above
it. No config of oauth2-proxy itself changed — only its reconciliation tier.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
Flux's postBuild.substituteFrom runs envsubst over the WHOLE manifest, including
the VM cloud-init userData. It was substituting every shell `${...}` in the UOS
install script (${UOS_URL}, the API-resolver ${...}) to empty — which is why the
first UOS install silently did nothing — and ${PIPESTATUS[0]} then broke the
build entirely ("missing closing brace"), blocking apps-vms reconcile.
VM manifests use no cluster-vars, so substitution is unneeded. Removed it; the
cloud-init shell now reaches the guest intact. (A future VM needing a cluster-var
must escape its shell `${...}` as `$${...}`.)
Co-Authored-By: Claude Opus 4.8 <[email protected]>
First KubeVirt VM app + first real CDI http import. UniFi OS Server (UOS) is
Ubiquiti's current self-host product (the .deb is deprecated); it bundles UniFi
OS + Network app + its own datastore, so no MongoDB companion.
- apps/vms/unifi: CDI DataVolume (Ubuntu 24.04 cloud image -> longhorn-vm
RWX/Block, live-migratable) + VirtualMachine (evictionStrategy: LiveMigrate)
with cloud-init that installs podman/slirp4netns/jq and runs the UOS installer
NON-INTERACTIVELY. The installer URL is resolved at boot from Ubiquiti's public
firmware API (fw-update.ui.com/api/firmware-latest) — always-latest, no pinned
URL to maintain (currently UOS v5.1.37).
- L4 exposure: two LoadBalancer Services (TCP+UDP) sharing a pinned, L2-announced
Cilium VIP 192.168.1.54 (device inform/adoption + STUN can't ride the L7
Gateway); external-dns publishes unifi.home.keithjackson.dev. UI on :11443.
- default-deny + additive CNPs (controller ingress, egress, and CDI-importer
egress for the image pull).
- clusters/base/apps-vms.yaml: NON-GATING Flux Kustomization (wait:false,
dependsOn platform-config) — VMs are a separate lifecycle from the app waves,
so a slow VM import/install can't stall the app tier.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
Replaces the single `apps` Flux Kustomization with dependency-ordered waves
(apps-wave-0..2) so a crashlooping workload isolates to its wave + downstream
instead of stalling the entire app tier. Parallel within a wave, ordered across.
- catalog/render.py: compute waves by longest dependency-path depth over the
ServiceDefinition `dependencies:` edges (a `<svc>-db` is a leaf, so its
consumer lands strictly higher — the "DB below consumer" rule falls out of
longest-path, no special case). `--emit-waves` generates the per-wave
kustomizations + Flux CRs; `--wave-layout` places renders into the right dir.
wave 0: pihole gitea jackett plex qbittorrent nextcloud-db semaphore-db
wave 1: sonarr radarr nextcloud semaphore gitea-actions
wave 2: seerr
- apps/*.yaml -> apps/wave-{0,1,2}/ (byte-identical moves; SOPS files intact).
- clusters/base: apps.yaml removed; apps-wave-{0,1,2}.yaml added (dependsOn
chain: platform-config -> wave-0 -> wave-1 -> wave-2, prune+wait each).
- clusters/dev: one SOPS decryption patch per wave (load-bearing).
- DESIGN-waves.md: wave table, topology, cutover runbook.
Cutover: preceded by disabling prune on `apps` (1bfb0db) so removing that
object here does not GC its resources; the wave Kustomizations SSA-adopt the
byte-identical manifests in place (no restart, no PVC churn).
Co-Authored-By: Claude Opus 4.8 <[email protected]>
Temporary: with prune:false, removing the `apps` Kustomization object in the
follow-up wave-split commit will NOT garbage-collect its owned resources
(CNPG Clusters -> PVCs). The apps-wave-* Kustomizations adopt them in place.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
Cut the GitOps source over from the bootstrap host-Gitea
(http://192.168.2.103:3000) to the now-healthy in-cluster Gitea at
https://gitea.home.keithjackson.dev. Public repo, LE-prod wildcard
cert publicly trusted, resolved in-cluster via coredns->Gateway, so
no secretRef/caCert needed. Bootstrap host-Gitea retained (stopped)
as a recovery path.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
Admission controller was crashlooping (9 restarts/4h, exit 255, NOT OOM:
live usage ~65Mi/384Mi limit, 7m cpu). Root cause: chart-default 100m CPU
request starved the process under node contention, so client-go calls hit
context-deadline-exceeded, leader-election lease renewal timed out, leadership
was lost and the webhook server closed. Raise the CPU request to 250m (no CPU
limit, to avoid CFS throttling) with modest memory headroom (256Mi/512Mi), and
raise dev admission replicas 1->2 so a single fail-closed pod restart no longer
502s cluster-wide admission-gated writes.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
oauth2-proxy + Grafana OIDC discovery to keycloak.home.keithjackson.dev failed x509
'unknown authority' — the wildcard was LE-staging (untrusted). Prod issuer is registered
+ Ready; switching ACME_CLUSTER_ISSUER dev override staging->prod re-issues a publicly
trusted cert. Needed for functional SSO (R-IDP) + R-TLS-01/03 'trusted'.
NOTE: the trusted-tls conformance test embeds the LE-staging root and must be updated to
the LE production root (ISRG Root X1) / system trust — follow-up.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
Parameterize the in-cluster split-horizon target as GATEWAY_VIP (R-ENV-02): base
default = dev L2-announced Gateway VIP (10.73.0.240, first IP of the Cilium LB pool).
coredns-custom answers *.home.keithjackson.dev with ${GATEWAY_VIP} so the unified graph
holds across dev/prod via cluster-vars only. Prod overlay carries a TODO to set the prod
LAN VIP alongside the prod L2 pool range when hardware is built.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
The in-cluster Gluetun gateway is retired; VPN egress is now a node-level host
OpenVPN split-tunnel (Ansible role vpn_egress_gateway) steered by a Cilium
Egress Gateway policy with a host nftables kill-switch (ADR-0015). Credentials
moved host-side to the Ansible vault. Update docs/comments only:
- platform/vpn-egress/README.md: rewrite for ADR-0015 (live + conformance-green);
drop the resolved "option 1 not viable with Gluetun" finding to a brief history note.
- platform/kustomization.yaml: Phase 3 comment -> node tunnel + Cilium steering.
- platform/kyverno/.../require-egress-class-label.yaml: ADR-0013 -> ADR-0015 steering.
- schemas/servicedefinition.schema.json: egress=vpn description -> node tunnel + Cilium.
- clusters/base/cluster-vars.yaml: reframe PIA_REGION / CLUSTER_POD_CIDR WHY comments
to ADR-0015 (Cilium excludedCIDRs); both keys retained (still referenced/documented).
- platform/vpn-egress/namespace.yaml: no privileged gateway pod under ADR-0015.
- pia-credentials.sops.yaml / pia-custom-ovpn.sops.yaml: comment headers only note
they are now UNUSED (creds host-side), retained pending cleanup; payloads untouched.
No runtime manifest behavior, alert exprs, kustomization resources, or SOPS payloads
changed. No spec-repo edits.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
PIA's PF gateway 10.31.128.1 sits inside the /8 cluster-pool, so
FIREWALL_OUTBOUND_SUBNETS=10.0.0.0/8 made gluetun route it around the tunnel and
port forwarding timed out (getSignature to 10.31.128.1:19999). /16 covers actual
pod allocations and excludes PIA's 10.31.x.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
CORRECTION: the connection failures were gluetun dialing RETIRED PIA IPs (46.246.x
= dead → timeouts, which I mis-read as a network block). A fresh PIA .ovpn connects
from the same host, and PIA's current SE Stockholm servers (158.173.x) are reachable.
Cilium was independently cleared (default-allow, host-fw off, Hubble FORWARDED).
Fix: UPDATER_PERIOD=24h so gluetun fetches PIA's current servers; keep
OPENVPN_MTU/MSSFIX=1350 for the real Cilium-VXLAN 1450 pod MTU (data channel);
PIA default UDP port. Re-enable vpn-egress. Full correction in DECISIONS-LOG.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
Decisive diagnosis: OpenVPN's outbound init packets are 14 bytes with zero
replies (so MTU was never the blocker), pod UDP egress is healthy (NTP replies),
but TCP 501/443 to PIA IPs time out while Google/Cloudflare are OPEN — across many
PIA servers. This 192.168.2.x WiFi segment blackholes PIA's IP ranges (and
intercepts DNS). Not code-fixable. Reverted the port/MTU red-herring env to PIA
defaults; disabled vpn-egress pending an operator network fix (move to the
unfiltered 192.168.1.x LAN, or unblock PIA on the router). Full trace in
DECISIONS-LOG.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
Port 53 also got no PIA replies: this network transparently intercepts outbound
:53, so dig works but OpenVPN-over-53 is swallowed. An NTP/123 probe from the host
returned fine, proving arbitrary non-53 UDP works bidirectionally (so it's
port-specific: 1197 conflict + 53 DNS-intercept, not a UDP block). Move to 8080
(community-verified for PIA, non-DNS, non-1197).
Co-Authored-By: Claude Opus 4.8 <[email protected]>
Wiring the port via "${PIA_OPENVPN_PORT}" made Flux/kustomize emit an unquoted
53 (int) after substitution, which k8s rejects for an env value ("expected
string, got 53"). Same gotcha as the Longhorn numberOfReplicas fix. Hardcode the
quoted string; cluster-var removed with a NOTE explaining why.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
Operator identified the block: the home network NATs its own OpenVPN server on
WAN:1197, colliding with the cluster's outbound PIA-on-1197 flow (port-specific,
not a general UDP block — UDP/53 worked in tcpdump). PIA accepts OpenVPN on
53/1194/1197/1198/8080/9201; chose 53 (empirically proven to traverse this net).
- cluster-vars: add PIA_OPENVPN_PORT="53"
- gluetun: OPENVPN_ENDPOINT_PORT=${PIA_OPENVPN_PORT}
- re-enable vpn-egress; DECISIONS-LOG resolution noted
Co-Authored-By: Claude Opus 4.8 <[email protected]>
Gluetun's PIA OpenVPN provider rejects "Sweden"; the valid PF-capable Sweden
region identifier is "SE Stockholm" ("SE Streaming Optimized" lacks port
forwarding). Preserves the operator's Sweden choice.
Co-Authored-By: Claude Opus 4.8 <[email protected]>
gluetun-gateway.yaml referenced ${PIA_REGION}/${CLUSTER_POD_CIDR} but they were never defined
in cluster-vars, and the README didn't say where to set them. Add both to
clusters/base/cluster-vars.yaml (ConfigMap data:, string values, Flux postBuild substitution).
CLUSTER_POD_CIDR is 10.0.0.0/8 (Cilium cluster-pool — pods get 10.x, confirmed live), NOT the
k3s 10.42.0.0/16 I'd assumed. README now names the file + format + per-env override + PF-region note.
Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
The on-cluster cluster-vars ConfigMap wasn't reconciled by Flux — this bootstrap
model had no Kustomization watching clusters/dev, so cluster-vars/overlay changes
needed a manual 'kubectl apply -k clusters/dev' (e.g. DNS_ZONE substituted empty
until re-applied). Add clusters/dev/sync.yaml: a self-managing root Kustomization
(flux2 gotk-sync pattern, name flux-system) that reconciles ./clusters/dev from git
— cluster-vars, the GitRepository, platform/platform-config/apps, and itself. A git
push now suffices. Bootstrap unchanged ('kubectl apply -k clusters/dev' creates it
once). Verified: dev build contains all 6 objects (root + existing), prod unaffected.
Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
Phase-2 exit tests (were Phase-0 scaffolds), authored against the live platform:
- trusted-tls (R-TLS-01/03): in-cluster probe dials the gateway Service (env-agnostic
via --connect-to) with wildcard SNI and verifies the served cert CHAINS TO THE LE
STAGING ROOT (operator decision A; dev uses LE-staging per ADR-0006). Fixture embeds
the '(STAGING) Pretend Pear X1' root. Probes public + internal-only hostnames (R-TLS-03).
PASSES.
- dns-exposure (R-DNS-02): a LoadBalancer Service with an external-dns hostname; polls
public DNS until ExternalDNS auto-publishes the record; teardown + policy=sync removes it.
ExternalDNS fix (root cause of the DNS test): domain-filter was the platform SUBDOMAIN
home.keithjackson.dev, which filters OUT the actual Cloudflare zone keithjackson.dev
('no hosted zone matching record DNS Name' — record generated but skipped). Add a
DNS_ZONE cluster-var (keithjackson.dev) and set domainFilters to it. policy=sync +
txt-registry still only manage ExternalDNS-owned records (the pre-existing wildcard is
untouched). Resolves the file's WS-NET R-DNS-02 TODO.
Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
Kyverno HelmRelease install failed at Helm templating: config.webhooks was a
LIST [{failurePolicy, namespaceSelector}], but the kyverno 3.3.9 chart expects
config.webhooks to be a MAP (webhooks.namespaceSelector) — the chart helper reads
.namespaceSelector off the value directly ('can't evaluate field namespaceSelector
in type []interface {}'). Also, failurePolicy is not a per-webhook field here; the
chart's global switch is config.forceFailurePolicyIgnore.enabled (bool).
Fix: config.webhooks -> map with namespaceSelector (system+platform excludes);
add config.forceFailurePolicyIgnore.enabled = ${KYVERNO_FORCE_FAILURE_POLICY_IGNORE}.
Renamed the cluster-var KYVERNO_WEBHOOK_FAILURE_POLICY (Fail/Ignore) ->
KYVERNO_FORCE_FAILURE_POLICY_IGNORE (false base / true dev). Verified with
helm template (renders 73 objects, no error); gate PASS.
Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
Un-suspend deadlocked: the single platform Kustomization applies HelmReleases
(which register CRDs) AND custom resources of those CRDs (ClusterIssuer,
Certificate, Kyverno ClusterPolicies) in ONE pass. Flux's server-side apply
fails atomically ('no matches for kind ClusterIssuer') → nothing installs, so
the CRD-registering HelmReleases never run either. Classic ordering deadlock.
Fix (flux2 controllers/configs pattern, applies to dev+prod equally — no
R-ENV-02 divergence): add a platform-config Flux Kustomization (dependsOn
platform, wait) carrying the CRs; platform keeps only the controllers.
- New clusters/base/platform-config.yaml (path ./platform-config, substituteFrom
cluster-vars, no decryption — no SOPS content); wired into base + apps now
dependsOn platform-config (transitively waits for platform).
- platform-config/ references the CR files IN PLACE via ../platform/... (Flux
builds LoadRestrictionsNone; Kyverno policies must stay under platform/kyverno/
for the CI L0 gate). CR resources dropped from the platform
component kustomizations (cert-manager, gateway, kyverno).
- Authored the missing Cilium L2 resources (were only a TODO): CiliumLoadBalancerIPPool
(dev NAT 10.73.0.240-.250) + CiliumL2AnnouncementPolicy (ens*), so Gateway
LoadBalancer listeners get a VIP. Prod range must be parameterized later.
Verified: platform build has zero CRs; platform-config build has 2 ClusterIssuers,
6 ClusterPolicies, Certificate, Gateway, both Cilium L2 CRs; dev/prod build; gate PASS.
Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
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]>
Flux postBuild.substituteFrom is case-sensitive; platform/ components reference
${UPPERCASE} tokens but cluster-vars keys were lowercase -> none would resolve
(literal ${...} would reach the HelmReleases). Uppercased the ConfigMap data
keys + the dev/prod overlay patch paths. Every component ref now resolves;
clusters/dev & clusters/prod build; gate green. Clears the K1 landmine before
any platform un-suspend.
Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
Run a single Gitea container on the host (bootstrap/gitea/), outside the cluster,
while the cluster is built; Flux pulls this repo from it over the k3s-dev NAT
gateway (http://10.73.0.1:3000/Home-Network/home-network-k3s-impl.git, public repo
=> no creds, NAT-only). Wired the flux-system GitRepository url in clusters/dev.
Migrates to in-cluster Gitea in Phase 6. Pins confirmed. Author-only; gate PASS.
Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
Phase 0 foundation shell (read-only spec at ../home-network-k3s). Top-level
tree + rules; workstream agents fill their subtrees on feature branches.
Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
