Commit Graph
22 Commits
Author SHA1 Message Date
jakman85andClaude Opus 5 b80e8eef82 feat(backup): prod shares dev's MinIO — plus the path tenancy that makes it survivable
Operator ruling: "the S3 backup location is the same as Dev." Prod's
S3_BACKUP_ENDPOINT is now http://192.168.1.9:9000 and the TBD-PROD-* placeholder
is retired. Set EXPLICITLY rather than by omitting the op — an omitted op would
inherit the same value silently, and a shared backup target must be visible in
the overlay that owns it.

SHARING THE ENDPOINT WAS NOT SAFE AS AUTHORED. Nothing about the backup PATHS
was per-environment, and enabling prod against dev's MinIO would have been the
2026-09-04 external-dns incident again, in a worse place:

  VELERO — bucket `velero`, NO prefix, and both clusters run schedules named
    `daily` / `daily-resources-only`. Velero SYNCS backups it finds in its BSL
    into itself as Backup CRs and GARBAGE-COLLECTS them at TTL, so prod would
    have adopted dev's backups and then deleted them on schedule.
  CNPG — the worse one. destinationPath `s3://cnpg` with CNPG appending
    serverName, which defaults to the CLUSTER NAME. Both environments have
    keycloak-db, nextcloud-db and semaphore-db, so prod's Postgres would archive
    WAL into the EXACT prefix dev's does. Two servers interleaving WAL into one
    Barman stream CORRUPTS THE CHAIN and destroys PITR — and dev's restore is
    PROVEN (R-STATE-03). Sharing an endpoint is fine; sharing a path is not.

Two knobs, authored once, environments differing only by scoped overrides
(R-ENV-02):
  VELERO_BACKUP_PREFIX  dev ""          | prod "prod"
  CNPG_BACKUP_PATH      dev "s3://cnpg" | prod "s3://cnpg/prod"

THE BASE VALUES ARE DEV'S CURRENT LAYOUT ON PURPOSE. Dev's existing backups live
at the bucket root and at s3://cnpg; giving dev a prefix would ORPHAN the very
backups its proven restore depends on — the same reasoning that keeps dev's
EXTERNALDNS_TXT_OWNER_ID at `default`. Prod has no history to preserve.

*** PROD STILL HAS NO BACKUP COVERAGE — the endpoint is not reachable. ***
Measured from a throwaway pod INSIDE the prod cluster (the workstation proves
nothing about pod egress, and a workstation-side reading has already misled this
project once): curl http://192.168.1.9:9000/minio/health/live → connection timed
out after 15s. pfSense does not route prod's pod network to the dev LAN's MinIO.
OPERATOR ACTION REQUIRED. velero stays suspended; note apps-wave-0 applies GREEN
regardless — the token IS defined so strict substitution succeeds — while every
write fails at RUNTIME. A green apps-wave-0 does not mean backups work.

New `standup.sh s3check` step probes the endpoint from a throwaway in-cluster
pod and fails closed, with `--s3-endpoint <url>` to test a CANDIDATE before
authoring it into cluster-vars. That is how the unreachability above was
established rather than assumed.

VERIFIED: full CI gate PASS. flux-postbuild-substitution 254 -> 260 assertions,
and neither new knob appears in the dead-knob advisory list, so both are really
consumed. Rendered both overlays: all three CNPG destinationPaths and Velero's
prefix carry the tokens; dev resolves to its existing layout, prod to the nested
paths.

DELIVERY: prod reconciles the bootstrap Gitea's main at c8c1d29. This branch also
carries the DNS inversion, which must NOT reach prod. Delivering needs a
c8c1d29-based branch with only these commits — no urgency while the routing is
still closed.

Refs R-STATE-03, R-ENV-02, R-IDP-05.

Co-Authored-By: Claude Opus 5 <[email protected]>
2026-09-05 10:59:50 -05:00
jakman85andClaude Opus 5 acb5cabdad fix(standup): preflight must always report — it was an env fork in disguise
preflight `die`d when EXTERNALDNS_TXT_OWNER_ID was empty, the sentinel, or
`default`. Two problems, found by pointing it at dev:

1. `default` is DEV'S LEGITIMATE owner id — its live records are registered
   under it and cannot be renamed without orphaning them. Dying on it meant a
   script whose entire claim is "environment-agnostic, no dev/prod fork"
   (R-ENV-02) could never run against dev at all. That is a fork in disguise.

2. Dev's value is currently EMPTY, because dev runs dev-live@a4a3c2e — based on
   main@4809199, which predates the commit that added the knob. That is dev's
   long-standing status quo, not a fault. The die hid the ENTIRE remaining
   health report behind it, which is backwards for a diagnostic.

preflight is now a pure diagnostic: it always finishes and reports, and the only
thing it refuses over is the --expect-server target guard, because that one
means you are pointed at the wrong cluster. Bad owner-id values are reported
with a warning explaining why each is dangerous and for whom.

THE REFUSAL MOVES, IT DOES NOT DISAPPEAR: step_externaldns — the MUTATING path,
where acting on a bad value is what actually deletes another cluster's records —
still dies on empty, sentinel and `default`. Verified both halves after the
change: prod preflight still reports "distinct and non-default: OK", and the
mutating guard is intact.

Confirmed with it: dev is 13/13 Kustomizations Ready on dev-live@a4a3c2e, all
HelmReleases Ready, nothing suspended — healthy throughout prod's standup.

Refs R-ENV-02.

Co-Authored-By: Claude Opus 5 <[email protected]>
2026-09-05 10:06:01 -05:00
jakman85andClaude Opus 5 4f37fc375e feat(prod): STANDUP COMPLETE — 12/13 tiers Ready, LE wildcard issued, dev untouched
Prod is up and serving. 113 pods, 0 not Running/Completed. wildcard-home
Certificate Ready (Let's Encrypt PROD, *.prod.home.keithjackson.dev). Gateway
VIP 192.168.2.20, crafty L4 .22, unifi L4 .21. 36 DNS records published under
prod.home.keithjackson.dev, every TXT registry entry owner=prod.

End-to-end HTTPS with certificate validation (no -k), pinned to prod's gateway:
apex 200, keycloak 302 (login), gitea 200, grafana 302 (SSO).

DEV UNTOUCHED: all 57 pre-existing records byte-identical to the pre-standup
baseline. velero remains suspended — S3_BACKUP_ENDPOINT is still the TBD
placeholder, and resuming it would create a BackupStorageLocation that can never
reach a bucket: a tier reporting healthy while backups silently do not exist.

TWO BUGS IN MY OWN VERIFICATION, both of which would have made the safety check
worthless. Recording them because a check you cannot trust is worse than none —
it trains you to skip the one alarm that matters.

1. SNAP_DIR defaulted to $TMPDIR. Every `dev.sh run` is a FRESH container, so the
   DNS baseline was discarded between steps and `verify`'s before/after
   comparison — the check that detects damage to the other cluster's records —
   could never run across invocations. Now repo-relative (bind-mounted, so it
   persists on the host) and gitignored as a run artifact.

2. The first real comparison cried wolf: "RECORDS OUTSIDE prod.home CHANGED",
   listing pairs of IDENTICAL lines. Cause was locale-dependent sort collation —
   the host ordered `*.keithjackson.dev` differently from the container, so a
   diff of two identical sets reported changes. Proved it was noise by
   re-comparing under LC_ALL=C: all 57 records identical. dns_snapshot now strips
   CRs and sorts under LC_ALL=C so ordering is reproducible everywhere.

ACTION REQUIRED (operator, pfSense): the local override is a wildcard on
*.home.keithjackson.dev and now also swallows the new prod.home.* subtree,
resolving EVERY prod hostname to 192.168.2.50 (dev). Cloudflare correctly
returns 192.168.2.20. Prod is reachable from anywhere using public DNS, but NOT
from behind pfSense. Narrow the override, or add one pointing prod.home.* at
192.168.2.20.

That override is also the trap that produced a false healthy reading during the
2026-09-04 incident, and it is subtle because it PARTIALLY works: dev's
*.home.keithjackson.dev wildcard matches prod.home.keithjackson.dev (one label)
so the apex returns 200 over valid TLS, while keycloak.prod.home... (two labels)
fails with a certificate-name error. I hit this myself during verification and
mistook it for a broken prod cert. Never verify DNS or TLS here through a local
resolver.

Refs R-ENV-02, R-GITOPS-01, R-PLAT-01.

Co-Authored-By: Claude Opus 5 <[email protected]>
2026-09-05 10:02:20 -05:00
jakman85andClaude Opus 5 1b056dc9d9 fix(prod): break the CDI cold-start deadlock, and make preflight catch its class
`platform-config` stopped dead on prod:

    StorageProfile/longhorn dry-run failed: no matches for kind
    "StorageProfile" in version "cdi.kubevirt.io/v1beta1"

A TRUE DEADLOCK, not a transient. platform-config applies the CDI CR *and*
platform/kubevirt/cdi-storageprofiles.yaml in the SAME pass. StorageProfile's
CRD does not exist until cdi-operator has reconciled that CR — and Flux
server-side dry-runs EVERY object before applying ANY of them, so the unknown
kind aborts the whole tier, the CR is never applied, the CRD is never created,
and platform-config can never converge. Every tier below it stays blocked.

Same root cause as the Kyverno CRD bundle, different operator: Flux cannot order
a resource against a CRD that one of its own siblings is responsible for
creating. It is INVISIBLE on an established cluster — dev's CDI CRDs have been
there for months — and fatal on a cold one. Observed on prod: cdi-operator
Available for 12h, no CDI CR, no storageprofiles CRD.

`crds` now breaks it by applying ONLY the CDI CR — the minimum — and leaving
every other object to Flux. The CR carries no ${} tokens, so applying it here
cannot diverge from what Flux would render. It refuses if the `cdi` namespace is
absent (platform has not run yet) rather than applying into nothing, waits for
the CRD, and requires it to reach Established. On prod the CRD appeared in 10s
and platform-config was unblocked.

`preflight` now reports the CRDs that later tiers apply resources against
(storageprofiles/cdis/kubevirts/volumesnapshotclasses) and dumps the cdi
namespace when one is missing, so this is caught in seconds instead of after
`resume` burns its 900s wait discovering it. It also names the stale-discovery-
cache variant, which presents identically but clears on a forced reconcile.

THE DURABLE FIX IS A REPO CHANGE, deliberately NOT made here: move
cdi-storageprofiles.yaml out of platform-config into its own Kustomization with
dependsOn: platform-config, so the CR lands one reconcile before the resources
needing its CRDs. That edits the reconciliation graph both clusters share, and
prod currently reads a pinned revision from the bootstrap Gitea while dev is
mid-migration on a separate branch — so it wants doing deliberately, not at
02:00 to unblock a bring-up. Until it lands, C2 is a prerequisite for C5 on any
cold cluster, and PROD-STANDUP.md says so.

Refs R-GITOPS-01, R-ENV-02.

Co-Authored-By: Claude Opus 5 <[email protected]>
2026-09-05 08:05:46 -05:00
jakman85andClaude Opus 5 4160fee6ce feat(prod): standup.sh + PROD-STANDUP.md — the complete standup sequence, in git
The last steps of a prod bring-up were living in shell history: resume the
tiers in the right order, clear a wedged HelmRelease, fix external-dns without
deleting the other cluster's DNS. That is the same failure the Kyverno CRD
pre-apply had, so it gets the same treatment.

bootstrap/standup.sh — environment-agnostic (R-ENV-02), no dev/prod fork. Six
idempotent steps: preflight, crds, unwedge, externaldns, resume, verify.

THE GUARD IS THE POINT. --expect-server is MANDATORY and is compared against
the live API server before any step runs; there is no override flag. Dev is
live and shares the keithjackson.dev Cloudflare zone with prod, and on
2026-09-04 prod deleted every one of dev's public records. Negative control
run: prod's kubeconfig with dev's server URL refuses and changes nothing.

preflight fails closed if EXTERNALDNS_TXT_OWNER_ID is empty, still the base
sentinel, or `default` (dev's owner) — the exact condition that caused the
incident. It also surfaces SUSPENDED HelmReleases separately, because a
suspended release keeps its last Ready condition and a stale `Ready=True`
otherwise hides that Flux is not managing it at all (external-dns today).

externaldns is the dangerous step, and the ordering IS the mitigation. A Helm
upgrade resets replicas to 1 and applies new args in ONE operation, so there is
no window to check the result first; if --txt-owner-id were missing the pod
starts as owner `default` and syncs away dev's records. So the step PROVES THE
OUTCOME BEFORE CAUSING IT: render the chart with the LIVE HelmRelease values and
assert --txt-owner-id=<owner> appears, aborting if not. Rendering is
deterministic and touches nothing, which turns a race into a precondition. Then
snapshot Cloudflare, upgrade, re-verify live args (scale to 0 and fail if
wrong), and diff the zone.

resume walks the dependency order and STOPS at the first tier that does not go
Ready — a partial understood bring-up beats a forced green. velero is skipped
while S3_BACKUP_ENDPOINT is the TBD placeholder.

TWO BUGS CAUGHT WHILE VALIDATING THIS, both by measuring instead of assuming:

1. preflight counted Kyverno CRDs with grep 'kyverno.io' and reported 20 of 22
   — the policy-report types are in the wgpolicyk8s.io group. A preflight that
   under-reports reads as "the pre-apply failed" when it succeeded. Fixed and
   re-run: 22.

2. The documented node-health invocation used -e k3s_hosts=k3s_prod and
   SILENTLY RAN AGAINST DEV'S THREE NODES. Diagnostic plays deliberately keep
   their own target var (node_health_hosts, memattr_survey_hosts,
   vpn_egress_gateway_hosts) so they stay pointable while a bring-up is scoped
   elsewhere — a good design I did NOT change. The hazard is that the wrong flag
   does not error, it falls through to the dev default. Caught only by
   --list-hosts; the doc now leads with that warning and a dry-run command.
   Verified after fixing: node-health and all six site.yml plays target prod.

.claude/settings.local.json — permission rules for the above. Every entry
hardcodes prod's kubeconfig AND prod's --expect-server (or prod's ansible
groups), so the permission strings are themselves prod-scoped and cannot be
turned against dev. Deliberately NO rule for `dev.sh run bash -c *`, which
would have been blanket cluster access wearing a narrow-looking mask.

Refs R-ENV-02, R-GITOPS-01, R-SEC-02.

Co-Authored-By: Claude Opus 5 <[email protected]>
2026-09-05 00:37:48 -05:00
jakman85andClaude Opus 5 13081a863f feat(bootstrap): automate the Kyverno CRD pre-apply — the last cold-start blocker
`platform/kyverno/admission/helmrelease.yaml` sets `crds: {install: false}`
because the CRD bundle is 5,636,155 bytes, far past kubectl's 256 KiB
last-applied-configuration limit — a client-side apply fails with
"metadata.annotations: Too long" and STALLS the HelmRelease.

The consequence nobody automated: with CRD install off, NOTHING installed
them. `platform` has `wait: true` and every other tier chains transitively
through it, so on a cold cluster Kyverno's API types never exist, `platform`
never goes Ready, and all 10 downstream tiers stall. Dev only ever had these
CRDs because they were applied BY HAND — exactly the undocumented manual step
this repo exists to eliminate.

New `bootstrap/flux/preapply-crds.sh`, wired into bootstrap.sh as step [2/4]
(after `flux install`, before the graph is applied) and standalone-safe so an
already-bootstrapped cluster can be unblocked without re-running bootstrap.

NO SECOND PIN: all four chart coordinates are read with yq out of the same
HelmRelease/HelmRepository pair Flux reconciles. The version is passed through
as the CONSTRAINT ("3.9.x"), not a resolved tag — helm and helm-controller both
use Masterminds/semver, so the render is the version Flux installs. Renovate
bumps one line and this step follows; there is nothing here to drift from.

Only `kind: CustomResourceDefinition` documents are applied. The by-hand
command recorded in the HelmRelease comment piped the WHOLE template into
kubectl, which would create Deployments/webhooks outside Helm's ownership and
then fight the HelmRelease over field managers.

THREE GUARDS, because a silent skip here reproduces a failure mode this repo
has been bitten by repeatedly:
  1. any derived coordinate that is empty/null/multi-valued aborts;
  2. rendered CRD count must be > 0 — this caught a real bug in the first
     draft: on an empty render `yq .metadata.name` emits one BLANK line, which
     counted as 1 CRD and sailed past the guard into an apply of an empty file
     returning 0, i.e. the exact silent-success trap. Blank/null lines are now
     dropped and a chart with no CRDs exits 1;
  3. every applied CRD is waited on for condition=Established, so "kubectl
     returned 0" is not the only evidence.
No opt-out flag, deliberately: a skipped CRD apply yields a cluster that looks
bootstrapped and reconciles nothing.

`roles/flux_bootstrap` is untouched — it already shells to bootstrap.sh, the
documented single entrypoint, so it inherits the step with no dev/prod fork
(R-ENV-02). A second role task would double-apply.

MEASURED, not assumed — reproduced under the PINNED toolchain (helm 3.16.0,
yq 4.44.6) in infra/devcontainer, matching an independent run on helm 3.20.0
byte-for-byte: 3.9.x resolves to 3.9.0, 22 CRDs, 5,636,155 bytes CRD-only
(5,870,019 full render). Largest single CRD document is 1,378,544 bytes —
under etcd's 1.5 MiB default, but not by much; worth watching on chart bumps.

NOT YET EXERCISED against a live API server: the server-side apply and the
Established wait were tested with a stub kubectl. velero and
kube-prometheus-stack also say "CRDs pre-applied" but both still get theirs
from Helm's native crds/ dir on FIRST install, so neither is a cold-start
blocker; CRD_HELMRELEASE makes extending this a one-liner if that changes.

Refs R-GITOPS-01, R-ENV-02.

Co-Authored-By: Claude Opus 5 <[email protected]>
2026-09-04 23:32:10 -05:00
jakman85andClaude Opus 5 9b8979a427 feat(prod): temp Gitea source + wireless disabled + flux bootstrap path
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]>
2026-09-04 18:53:17 -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 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 36a1a4e1f9 refactor(apps): split monolithic apps Kustomization into dependency waves
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]>
2026-08-26 12:19:00 -05:00
jakman85andClaude Opus 4.8 c6301a79c5 fix(bootstrap): subshell the repo_root fallback so trailing pwd doesn't corrupt the path
Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-25 12:27:34 -05:00
jakman85andClaude Opus 4.8 37f4fa6767 feat(updates): install Flux image controllers + cluster-wide write-back engine (R-UPD-02)
Install image-reflector-controller + image-automation-controller as part of the
flux-system install (bootstrap.sh --components-extra) so the image.toolkit CRDs
pre-exist before reconcile — no F-MON1 split needed for the ImageUpdateAutomation CR.
Refine the cluster-wide ImageUpdateAutomation for machine-authored git write-back
(setter strategy, path ./apps) reusing the flux-system GitRepository secretRef, and
document the operator git-write-credential hand-off + SOPS secret template
(gitea-image-automation-credentials). image-automation stays deferred in
platform/kustomization.yaml until that credential is provisioned.

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-24 22:14:39 -05:00
jakman85andClaude Opus 4.8 91aa7acab8 wip(vpn): gluetun custom-provider mode with operator's PIA .ovpn
PIA-provider server selection is flaky here (random dead IPs); the operator's .ovpn
uses sweden.privacy.network (load-balanced, reliable). Switch to custom mode
(VPN_SERVICE_PROVIDER=custom, OPENVPN_CUSTOM_CONFIG=/config/pia.ovpn), mount the
pia-custom-ovpn Secret, keep creds + kill-switch + tun-mtu 1300. Drops PIA-provider
server list/updater and native PF (Phase-6 concern). Pending the operator-provisioned
pia-custom-ovpn Secret (not merged until it exists).

Co-Authored-By: Claude Opus 4.8 <[email protected]>
2026-08-23 00:40:08 -05:00
jakman85andClaude Opus 4.8 1a98429434 feat(phase3): author shared VPN egress gateway (Gluetun/PIA/WireGuard) — author-first
Per ADR-0013: platform/vpn-egress/ = a single shared Gluetun gateway (PIA over WireGuard,
built-in kill-switch FIREWALL=on, native port forwarding), namespace (non-app, NET_ADMIN +
/dev/net/tun), control-API Service, and a pre-wired (commented) pia-credentials SOPS line.
Defined the PIA secret location (platform/vpn-egress, keys username/password → OPENVPN_USER/
OPENVPN_PASSWORD) and updated the SOPS template accordingly.

NOT wired into platform/kustomization.yaml (Phase 3, author-first) — deploy needs PIA creds +
validation of the egress-steering mechanism (Cilium Egress Gateway → the Gluetun node's wg0;
documented in README with options + a fail-closed rationale, deliberately NOT committed as an
untested CiliumEgressGatewayPolicy). WireGuard chosen (UDP, protocol != TCP); PIA supports it on
all regions and the secret stays username/password.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
2026-08-21 22:19:22 -05:00
jakman85 06fa317063 Added fixes before token usage cutoff. Added required credentials for dns api for cert-manager and external-dns 2026-08-16 23:12:25 -05:00
jakman85andClaude Opus 4.8 4f3be7ef79 docs(sops): exact Cloudflare token creation steps (Zone scope, not Account)
The terse 'Zone->DNS->Edit + Zone->Read' sent the operator to the Account
permission scope. Spell out switching the scope dropdown to Zone + the exact
two Zone-scoped rows + Specific-zone resource.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
2026-08-16 22:41:02 -05:00
jakman85andClaude Opus 4.8 a108d5ab98 correction: credential-forward + unified graph; activate SOPS (author-first)
Operator directive: don't diverge architecture to avoid asking for credentials;
provision them upfront via SOPS and keep the existing (unified) graph.

Roadmap reconciliation: Phase 2 = Network/Storage/TLS/DNS/Ingress, so
cert-manager/externaldns/gateway (the credential-gated pieces) ARE Phase 2;
monitoring is Phase 4. Earlier A2/rollout scope was inverted by credential-avoidance.

Reverts (credential-driven): remove clusters/dev/rollout/ + the $patch:delete's;
restore unified base graph (dev = ../base + cluster-vars + SOPS decryption,
R-ENV-02 intact); restore monitoring files (Phase 4). Kept non-credential
improvements: tofu for_each/rejoin, Kyverno parametrization + webhook excludes.

platform/kustomization.yaml now phased (single shared list): Phase-2 set =
kyverno, cilium, longhorn, cert-manager, externaldns, gateway; later components
commented with phase markers.

SOPS activated: .sops.yaml at repo root; bootstrap/sops/secret-templates/*.yaml.example
for all secrets (cloudflare x2, grafana, alertmanager-smtp, keycloak, oauth2-proxy, pia);
bootstrap/sops/CREDENTIALS.md checklist; pre-wired commented cloudflare-api-token lines
in cert-manager + externaldns; filled non-secret ACME email. Agents never touch real
secret values (operator encrypts).

Validated: kubectl kustomize dev(unified)/prod/platform(Phase-2 only), templates inert,
make -C ci gate PASS.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
2026-08-16 22:09:20 -05:00
jakman85andClaude Opus 4.8 3df5071bd1 Codify host firewall + Gitea bootstrap as IaC (hands-off rebuild)
Per operator: the firewalld rule (VM->host:3000 for the Flux<-Gitea source) must be
IaC, not a manual command (R-ENV-01, R-PLAT-04).
- infra/ansible/playbooks/host-prereqs.yml: idempotent firewalld open on the libvirt
  zone (localhost play, become; no extra collection).
- bootstrap/gitea/bootstrap-gitea.sh: now fully automates admin + public repo + push
  (was manual instructions) — idempotent; creds stay 0600 on host, never committed.
Applying host-prereqs still needs host sudo (I lack non-interactive sudo); with
passwordless become a destroy/rebuild is fully unattended.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
2026-08-16 14:52:08 -05:00
jakman85andClaude Opus 4.8 cc89b4b830 Autonomous session: Phase-2 platform authoring + Flux bootstrap progress
Author-only Phase-2 components (platform suspended; cluster untouched):
- platform/longhorn: 3-replica SC + bulk external-mount indirection (R-STATE)
- platform/monitoring: kube-prometheus-stack + Loki + Alloy (dev-trimmed) + 8 alert rules (R-OBS)
- platform/cilium: parity fix (k8sServiceHost=10.73.0.11 + masquerade) safe to adopt Phase 2
- conformance: partial L2 tests (worker hit session limit; incomplete — see DECISIONS-LOG K2)
- bootstrap/gitea: fix rootless-podman perms (host bind-mount -> named volume)

Flux installed on the cluster; host Gitea up + repo pushed; GitRepository BLOCKED by
host firewalld (VM->10.73.0.1:3000) — needs one operator sudo command (DECISIONS-LOG).
Known issue K1: cluster-vars substitution-var case mismatch (fix before un-suspend).

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
2026-08-16 14:32:47 -05:00
jakman85andClaude Opus 4.8 e6b4062310 Phase 1: host Gitea as the bootstrap GitOps source (resolves source-URL)
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]>
2026-08-16 01:26:47 -05:00
jakman85andClaude Opus 4.8 84a2d762f0 Phase 1 (author-only): Flux + SOPS bootstrap + interface wiring (T-1.4)
bootstrap/sops (age-keygen refusing in-repo, .sops.yaml, install-age-key.sh
glue installing the sops-age Secret) + bootstrap/flux (bootstrap.sh: flux
install -> apply -k clusters/dev; decryption/url patches). PM wiring: place
.sops.yaml at repo root (SOPS walks to root); inline the 3 flux patches into
clusters/dev (avoids kustomize ../ load-restriction). clusters/dev builds with
decryption enabled; full CI gate PASS. No key material; nothing executed.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
2026-08-16 01:21:01 -05:00
jakman85andClaude Opus 4.8 5ba9238cc1 Scope Phase 1: dev/test cluster bring-up on local KVM
Add infra/PHASE1-SCOPE.md (grounded in local recon: 24c/22GiB-avail/137G,
AMD-V+libvirt ready; OpenTofu/age/sops/flux missing) + infra/ and bootstrap/
structure stubs. Maps T-1.1..T-1.5; resource/network plan; risks; acceptance
gates; operator decisions. No spec edits; gate green.

Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
2026-08-16 00:48:48 -05:00