jakman85andClaude Opus 5
9f59c36000
Operator ask: implement the roles needed to check prod node hardware health, and run them to find out our state. This is that role; the run's findings are below. roles/node_health is a read-only sibling to cluster_verify (cluster health vs hardware health), styled after node_baseline. One unprivileged collector script does the work in a single SSH round trip — reading /sys/class/dmi, thermal + hwmon, EDAC, cpufreq + thermal_throttle, /proc/pressure, /sys/block incl. SCSI ioerr/iotmo counters, lsblk, lscpu, mounts + statvfs, per-NIC stats, resolv.conf. THE DESIGN POINT: an unreadable field is emitted as null WITH A RECORDED REASON, never as zero. The summary ends with a "NOT READ (and why) — these are UNKNOWNS, not passes" section. A fake zero on a reallocated-sector count is exactly the kind of false green this project refuses. 22 checks report PASS/WARN/FAIL/SKIP/INFO; every SKIP says why. Report-only by default; thresholds live in defaults/main.yml. Portable across bare metal AND VMs — validated against k3s-prod-1 (bare metal, no root) and k3s-dev-1 (VM, root). VM-absent things (SMART on virtio, coretemp, EDAC) skip cleanly, and iSCSI/Longhorn volumes are split out of the physical-disk set so a live replica is never mistaken for a spare device. playbooks/node-health.yml takes its target group as a variable (-e node_health_hosts= k3s_prod), deliberately unlike the other playbooks that hardcode k3s_servers — see the group-name gap already flagged in hosts.ini. Two become facts found the hard way and documented in the role: a group_vars `ansible_become: true` OUTRANKS `become: false` as a play/task keyword, so unprivileged tasks must override the variable; and `failed_when: false` does NOT catch "Missing sudo password" — only `ignore_errors` does. FIRST RUN, k3s-prod-1, 2026-08-31: 0 FAIL · 3 WARN · 12 PASS · 3 SKIP · 4 INFO. Box is healthy, cool and unstressed: i7-9700T 8C/8T, VT-x + /dev/kvm (KubeVirt OK), zero throttle events, hottest sensor 33C, PSI 0.00 across the board, 31.1 GiB RAM, eno1 up at 1000 Mb/s, BIOS R21 02.26.00, no reboot pending. DRIVE HEALTH IS STILL UNKNOWN — the headline. SMART did not run, blocked TWICE over: no vaulted ansible_become_password for prod, AND smartmontools is not on the node at all (node_baseline has never run there). Power-on hours, wear, reallocated/pending sectors and drive temperature all remain unmeasured on a ~2011 consumer SSD. WARNs: kernel ioerr_cnt=6 on sda (read cautiously — four freshly attached iSCSI disks on dev each showed a flat 7, suggesting a fixed per-device discovery cost, not media trouble; attribution needs dmesg/root); 0.95 GiB swap still active (node_baseline does the swapoff); one IPv4 resolver only (the other two upstreams are IPv6 Google), which refines rather than resolves the DNS-SPOF finding. ESCALATION — ECC status is UNKNOWABLE on this hardware: /sys/devices/system/edac/mc exists but no controller is bound. Non-ECC consumer RAM. Silent memory corruption on a prod node would be undetectable. Recorded as a SKIP with reason, not a pass. Serves: R-ENV-01, R-ENV-03, R-OBS-04. Task: T-7.1. Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
infra/ansible — k3s HA + Cilium bootstrap (Phase 1 T-1.3)
The "Cluster-join" node lifecycle stage (docs/02 stage 3) and the Flux hand-off
(T-1.4 call-in). Installs a 3-server HA k3s cluster (embedded etcd), Cilium as the
CNI, verifies readiness, then invokes the bootstrap/ entrypoints.
LIVE. These plays have been executed against the running dev cluster (k3s v1.36.4+k3s1, 3 nodes). This is no longer author-only scaffolding — treat it as the operational bring-up + re-provision runbook. See Re-provisioning a node below.
Serves R-ENV-01/02, R-PLAT-01, ADR-0001 (k3s), ADR-0002 (Cilium), ADR-0004 (Flux hand-off), ADR-0007 (SOPS).
Prerequisites
tofu applyin../tofu/has created the VMs; cloud-init (../cloud-init/) has baselined them (modules, sysctls, Longhorn disk, SSH user).- Inventory reflects the node IPs.
inventory/hosts.iniships aligned with the LOCKED defaults; regenerate from tofu if overridden:cd ../tofu && tofu output -raw ansible_inventory > ../ansible/inventory/hosts.ini - Run from the dev container (has
kubectl+helm, used by the Cilium/verify/ Flux plays viadelegate_to: localhost).
Run order
cd infra/ansible
ansible-playbook playbooks/site.yml # core bring-up, in order (baseline→k3s→cilium→verify→flux)
# — or step by step —
ansible-playbook playbooks/node-baseline.yml # 0. packages, kernel modules, Longhorn disk, swap-off
ansible-playbook playbooks/k3s.yml # 1. HA k3s (primary --cluster-init, then joins)
ansible-playbook playbooks/cilium.yml # 2. Cilium CNI (cluster is NotReady until this)
ansible-playbook playbooks/verify.yml # 3. gate #1: 3 nodes Ready, Hubble up, no kube-proxy
ansible-playbook playbooks/flux-bootstrap.yml # 4. hand off to bootstrap/ (SOPS then Flux)
site.ymlis NOT everything. It covers the core bring-up only. Two node-host layers live OUTSIDEsite.ymland must be run separately:ansible-playbook playbooks/kube-vip.yml # control-plane VIP (192.168.1.49); targets k3s_servers ansible-playbook playbooks/vpn.egress.gateway.yml # node-host OpenVPN split-tunnel + kill-switch; targets k3s-dev-3
Re-provisioning a node (tofu -replace / fresh OS)
A node rebuild wipes everything on the host filesystem — including host-level config
that Flux/Helm do NOT manage. After tofu apply/-replace re-creates a node, re-run the
node-host layers or the node comes back missing pieces:
| Re-run | Why it doesn't survive a rebuild |
|---|---|
node-baseline.yml |
packages (incl. cryptsetup), kernel modules, Longhorn disk, swap-off |
k3s.yml |
the k3s server binary + config + join (secondaries re-join the VIP) |
kube-vip.yml |
the kube-vip auto-deploy manifest on the server's host path |
vpn.egress.gateway.yml |
the OpenVPN (PIA) client, tun0, systemd units + nftables kill-switch on k3s-dev-3 — miss this and egress-class=vpn pods (sonarr/radarr/qbittorrent) are kill-switch-dropped with no internet |
Everything Flux owns (platform + apps) self-heals once the node re-joins; only the
node-host layers above need a manual re-run. Verify the VPN after: on k3s-dev-3,
systemctl is-active vpn-egress-tunnel.service and curl --interface tun0 https://ipinfo.io/ip
should return a PIA exit IP (not the home ISP).
What each layer does
| Playbook / role | Action |
|---|---|
k3s.yml / k3s_server |
k3s server install with --flannel-backend=none --disable-kube-proxy --disable-network-policy --disable=traefik,servicelb; primary --cluster-init, secondaries join via the primary's node-token (fetched, never pre-stored) |
cilium.yml / cilium |
Gateway API CRDs, then Helm cilium with kubeProxyReplacement, k8sServiceHost/Port, gatewayAPI, egressGateway, hubble, l2announcements |
verify.yml / cluster_verify |
waits nodes Ready + Cilium/Hubble rollout; asserts kube-proxy absent |
flux-bootstrap.yml / flux_bootstrap |
calls bootstrap/ (SOPS age key, then flux bootstrap --path=clusters/dev) |
Cilium ownership / parity contract (docs/02)
Ansible installs Cilium; the Flux platform/cilium HelmRelease adopts config
afterward. The parity-critical values must match between this role's
templates/cilium-values.yaml.j2 and that HelmRelease:
kubeProxyReplacement: truek8sServiceHost: {{ k3s_api_host }}(= primary node IP,10.73.0.11by default)k8sServicePort: 6443
The HelmRelease currently has k8sServiceHost: "REPLACE-ME" — WS-NET must set it
to the same value this role uses (surfaced by tofu output primary_node_ip).
Interface assumed of bootstrap/ (authored by other workers, NOT here)
roles/flux_bootstrap invokes two entrypoints via overridable command vars:
flux_bootstrap_sops_cmd→bootstrap/sops/install-age-key.sh(Security Engineer, T-1.4): installs the age private key as thesops-ageSecret influx-system. Key never committed (.gitignoreguardsage.key/*.key).flux_bootstrap_flux_cmd→bootstrap/flux/bootstrap.sh(GitOps Engineer, T-1.4): runsflux bootstrap ... --path=clusters/dev.
These script names/args are assumptions — if the bootstrap deliverables
expose different entrypoints, override the two vars in
roles/flux_bootstrap/defaults/main.yml; the task graph is unchanged. Flagged
for PM reconciliation.
Prod inventory — scaffolding only, Phase 7 PREP (nothing above is run against it)
inventory/hosts.ini also carries a [k3s_prod_primary] / [k3s_prod_secondary] /
[k3s_prod:children] section for the three planned bare-metal nodes (k3s-prod-1 at
192.168.2.10 exists and is reachable today; k3s-prod-2/-3 at .11/.12 are addressed but
not yet racked, so their inventory lines stay commented out), with its own group_vars/k3s_prod/
(vaulted ansible_become_password + non-secret overrides). Note 192.168.2.20 is prod's
ingress Gateway VIP (a Flux/cluster-vars concern, not an Ansible one — it does not appear in
group_vars/k3s_prod/); the kube-vip control-plane VIP (kube_vip_address) is a separate,
still-undecided address, left as a loud BLOCKED placeholder alongside the node_baseline device
overrides. See group_vars/k3s_prod/README.md and infra/PROD-PROVISIONING.md (T-7.1) §4/§2 for
the open decisions that still block a real run.
Everything else in this README describes the dev runbook. It does not (yet) apply to prod
as-is: the run order above and the roles it calls (k3s_server, cluster_verify, ...) target the
literal k3s_primary / k3s_secondary / k3s_servers groups, not k3s_prod_* — see the GAP note
at the top of inventory/hosts.ini's prod section for what's still missing before that reuse (the
R-ENV-02 promise) actually works end to end.
Static validation (PM, in dev container — NOT run here)
yamllint -c ../../ci/yamllint.yaml infra/ansible
ansible-playbook -i inventory/hosts.ini --syntax-check playbooks/site.yml
ansible-lint playbooks/ roles/ # if the profile is enforced for infra/