jakman85andClaude Opus 5
05baae90ec
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]>
130 lines
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130 lines
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---
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# cluster-vars — the overlay knob surface (R-ENV-02).
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#
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# This ConfigMap holds BASE DEFAULTS. Flux `postBuild.substituteFrom` injects these into every
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# `${TOKEN}` in platform/ and apps/ manifests at reconcile time. dev/ and prod/ overlays STRATEGIC-
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# MERGE PATCH this single ConfigMap — that patch is the *entire* difference between environments.
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#
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# Add a knob here (with a base default) before referencing `${KNOB}` in a component manifest, then
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# give each overlay its env-scoped value. Never fork a base manifest to differ per environment.
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apiVersion: v1
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kind: ConfigMap
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metadata:
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name: cluster-vars
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namespace: flux-system
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data:
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# --- identity of the environment ---
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CLUSTER_ENV: "base" # dev | prod (overlays set this)
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# --- DNS / TLS ---
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BASE_DOMAIN: "home.keithjackson.dev" # platform hostname suffix (same both envs; split-horizon)
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DNS_ZONE: "keithjackson.dev" # the actual Cloudflare ZONE (BASE_DOMAIN is a subdomain of it);
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# ExternalDNS domain-filter must be the zone, not the subdomain
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ACME_CLUSTER_ISSUER: "letsencrypt-staging" # dev: staging | prod: letsencrypt-prod (ADR-0006)
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GATEWAY_VIP: "192.168.1.53" # in-cluster split-horizon target (R-DNS-01/03): the L2-announced
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# ingress VIP of the `shared` Gateway. MUST equal the FIRST address of
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# ${CILIUM_LB_POOL_START}..${CILIUM_LB_POOL_STOP} below — the Gateway
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# takes the pool's first free IP, and coredns-custom answers
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# *.home.keithjackson.dev with THIS so pod -> public-hostname traffic
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# hairpins through the Gateway (correct SNI -> wildcard cert).
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# Base default = the DEV LAN VIP (was 10.73.0.240, an address on the
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# long-RETIRED libvirt network — corrected 2026-08-31 so an overlay that
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# forgets this knob at least lands on a REAL network). A prod overlay
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# MUST still set the prod LAN VIP alongside the prod L2 pool range.
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# --- LAN addressing (R-ENV-02) — the ONE block every new environment must re-supply -------------
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# These were HARDCODED into base manifests until 2026-08-31, which broke the golden constraint:
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# `clusters/prod` would have rendered the DEV LAN (192.168.1.0/24) onto the prod LAN (192.168.2.0/24)
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# — a silent, cross-environment IP collision. They are knobs now. Base defaults ARE the dev values
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# (same convention as GATEWAY_VIP above: the base default is the known-good working value), so the
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# dev overlay restates them verbatim and a prod overlay MUST override EVERY knob in this block
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# before `flux bootstrap --path=clusters/prod`.
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#
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# Substitution coverage (verify before adding a knob here): every path that consumes these declares
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# postBuild.substituteFrom cluster-vars — platform (K3S_API_HOST), platform-config
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# (CILIUM_LB_POOL_*, S3_BACKUP_ENDPOINT), crafty (CRAFTY_L4_VIP), apps-wave-0 (S3_BACKUP_ENDPOINT),
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# velero (S3_BACKUP_ENDPOINT), apps-vms (UNIFI_L4_VIP). A ${TOKEN} in an UNSUBSTITUTED path would
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# ship the literal string into the cluster.
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# k3s API endpoint Cilium's kube-proxy replacement dials (platform/cilium/helmrelease.yaml).
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# [parity] MUST equal the Ansible bootstrap's k3s_api_host (infra/ansible/roles/cilium/defaults/
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# main.yml -> cilium-values.yaml.j2, already inventory-parameterized). Wrong value = Cilium cannot
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# reach the API server on adopt and the CNI breaks. Port stays 6443 in both envs, so it is NOT a knob.
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K3S_API_HOST: "192.168.1.50"
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# CiliumLoadBalancerIPPool `default-pool` (platform-config/cilium/l2-ip-pool.yaml): the VIP range
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# L2-announced on the flat LAN. Must sit OUTSIDE the node IPs and any DHCP scope, and must match the
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# tofu reservation (cilium_l2_vip_range). INVARIANT: ${GATEWAY_VIP} must be INSIDE this range and in
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# practice EQUAL to START — the `shared` Gateway pins no address, so LB-IPAM hands it the pool's
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# first free IP. (⚠ the operator-supplied PROD values currently break this; see l2-ip-pool.yaml and
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# the flagged block in clusters/prod/kustomization.yaml.)
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CILIUM_LB_POOL_START: "192.168.1.53"
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CILIUM_LB_POOL_STOP: "192.168.1.60"
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# Pinned VIPs carved out of that pool by name (lbipam.cilium.io/ips). These are L4 workloads the
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# HTTPS Gateway cannot express (raw TCP/UDP), so they hold their own stable address:
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UNIFI_L4_VIP: "192.168.1.54" # UniFi controller VM: inform/STUN/adoption (apps/vms/unifi)
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CRAFTY_L4_VIP: "192.168.1.55" # Crafty: Minecraft Java (TCP) + Bedrock (UDP) game ports
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# Off-cluster S3 backup target (R-STATE-03, R-IDP-05) — the on-Proxmox MinIO, plain HTTP, path-style.
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# Consumed by BOTH backup paths: every CNPG Cluster's barmanObjectStore.endpointURL (keycloak-db,
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# nextcloud-db, semaphore-db) and Velero's backupStorageLocation s3Url. Full URL incl. scheme+port.
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# Prod needs its OWN target: a backup that lands on the dev LAN's MinIO is not off-cluster DR.
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S3_BACKUP_ENDPOINT: "http://192.168.1.9:9000"
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# --- storage (ADR-0003) ---
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LONGHORN_DEFAULT_REPLICA_COUNT: "3" # default StorageClass replica count (3 on 3 nodes)
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# Longhorn's defaultDataPath (platform/longhorn/helmrelease.yaml): the on-NODE directory every
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# replica is written into. It must be the path the NODE's own data disk is actually mounted at —
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# roles/node_baseline owns that half (node_baseline_longhorn_data_path), and the two are ONE
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# fact stated in two places, so [parity] holds per environment or replicas land on the OS disk.
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# Base default = the DEV value, same convention as GATEWAY_VIP / the LAN block: the known-good
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# working value. Dev's dedicated /dev/vdb IS mounted here and the LIVE cluster has 18 volumes
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# on it — changing dev's value would orphan every replica, so the dev overlay restates it
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# verbatim. PROD DIFFERS: its data partition serves TWO tenants (Longhorn plus k3s's whole data
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# dir, moved off the 11.8 GiB /var — infra/PROD-PROVISIONING.md §2), so it is mounted at the
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# neutral /data and Longhorn gets the /data/longhorn SUBDIRECTORY, not the mount root.
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LONGHORN_DATA_PATH: "/var/lib/longhorn"
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# --- observability sizing (docs/10) ---
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MONITORING_PROMETHEUS_RETENTION: "7d" # dev short | prod long
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MONITORING_PROMETHEUS_PVC_SIZE: "10Gi"
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# SIZE-based retention cap for Prometheus (Prometheus *iB units, NOT the K8s `Gi` of the PVC knob).
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# MUST stay below MONITORING_PROMETHEUS_PVC_SIZE — leaves headroom for the WAL + head + compaction
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# scratch (retentionSize counts only persisted blocks). Prevents a busy TSDB from filling /prometheus
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# (a full disk wedges all WAL commits and makes every absent()/==0 alert fire falsely). Base 10Gi PVC.
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MONITORING_PROMETHEUS_RETENTION_SIZE: "8GiB"
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MONITORING_LOKI_PVC_SIZE: "10Gi"
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# --- admission enforcement (Kyverno, ADR-0011). Base defaults are the STRICT/prod posture;
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# the dev overlay softens them for bootstrap (Audit / Ignore / 1) so a cold cluster can
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# come up before policies are proven and admission is HA. ---
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KYVERNO_VALIDATION_ACTION: "Enforce" # dev: Audit (observe before enforcing)
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KYVERNO_FORCE_FAILURE_POLICY_IGNORE: "false" # dev: "true" (chart forceFailurePolicyIgnore = fail-open)
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KYVERNO_ADMISSION_REPLICAS: "3" # dev: 1 (no HA needed to iterate)
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# --- egress / VPN (Phase 3, ADR-0015) — node-level host OpenVPN tunnel steered by Cilium Egress
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# Gateway (platform/vpn-egress/egress-steering.yaml). No in-cluster gateway pod. ---
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PIA_REGION: "SE Stockholm" # PF-capable PIA region (Sweden). Under ADR-0015 the tunnel is
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# host-side (Ansible vault / the node's .ovpn per docs/07), so this
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# is now a reference default only — retained, not substituted into
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# any manifest. ("SE Stockholm" is PF-capable; NOT "SE Streaming
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# Optimized" / a US region, which lack PF.)
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CLUSTER_POD_CIDR: "10.0.0.0/16" # Documents the Cilium cluster-pool pod CIDR that the egress-steering
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# CiliumEgressGatewayPolicy carves out of the tunnel via excludedCIDRs
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# (kept on the LOCAL datapath, never SNAT'd out tun0). The policy
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# currently excludes the whole /8 RFC1918 range; this /16 records the
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# actual pod allocations (Cilium assigns /24 per node from 10.0.0.0 up).
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# --- identity / auth (ADR-0014) ---
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KEYCLOAK_REPLICAS: "1" # dev 1 | prod 2 (HA)
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OAUTH2_PROXY_REPLICAS: "1" # dev 1 | prod 2 (HA)
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# --- backup / DR (ADR-0003, R-STATE-03) ---
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VELERO_BACKUP_SCHEDULE: "0 3 * * *" # cron; overlays may differ
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VELERO_RETENTION: "168h" # dev short | prod long
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# --- placement ---
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PLATFORM_NODE_SELECTOR_KEY: "kubernetes.io/os" # base no-op selector; prod may pin roles
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PLATFORM_NODE_SELECTOR_VALUE: "linux"
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