jakman85andClaude Opus 5
e3c44368c8
Two operator corrections: 1. PROD DOES NOT GET NOPASSWD SUDO. My initial checklist recommended mirroring dev's passwordless sudo onto prod — rejected, correctly. Dev's NOPASSWD is a convenience that must not propagate to production. Prod instead keeps a real sudo boundary and drives Ansible `become` with an ansible-vault-encrypted `ansible_become_password` in inventory/group_vars/k3s_prod/vault.yml, mirroring the EXISTING hypervisor and proxmox_hosts groups. The decrypting passphrase stays outside the repo at ~/.config/home-k3s/ansible-vault-pass (ansible.cfg :: vault_password_file), so plays still run unattended with no plaintext secret in git. 2. THE TASK BOARD IS NOT THE STATUS SURFACE — THE REPOSITORY IS. Operator ruling closes the escalation raised in the previous commit. Requirement/spec status is to be DERIVED from repo state (what is authored, reconciled, and covered by a green requirement-tagged test), not from a hand-maintained board. The spec board is left as a historical seed; no agent edits it and no SPEC_PIN churn is spent on it. ci/spec-immutability.sh keeps its full strictness — no path exception was added, since weakening an R-TEST-06 gate for a bookkeeping file would be a defect, not a fix. A repo-derived spec status report becomes the artifact of record alongside the coverage report and this log. Serves: R-ENV-03 (prod provisioning posture), R-SEC-01 (no plaintext secrets), R-TEST-06. Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
203 lines
12 KiB
Markdown
203 lines
12 KiB
Markdown
# Prod bare-metal provisioning checklist (T-7.1)
|
||
|
||
**Task:** T-7.1 · **Workstream:** WS-INFRA · **Serves:** R-ENV-01, R-ENV-02, R-ENV-03, R-PLAT-01/03
|
||
**Status:** Phase 7 **opened by the operator 2026-08-31** — *prep only*. Nothing is installed on prod
|
||
hardware until the blockers in §7 are closed and `make -C ci gate` is green.
|
||
|
||
> **Entry-gate note (recorded, not waived).** `roadmap/phases.md` gates Phase 7 on *"Phases 1–6
|
||
> proven in dev/test; operator declares prod hardware ready."* The operator has declared hardware
|
||
> ready. The first condition is **not** met: conformance is 37/51, and the uncovered set includes
|
||
> **R-ENV-01/02/03** — the very requirements this document serves. We proceed with prep work
|
||
> knowingly; see `DECISIONS-LOG.md` (2026-08-31 Phase-7 entry).
|
||
|
||
Prod is **3× mini-PC bare metal** ([spec docs/02](../../home-network-k3s/docs/02-environments-and-provisioning.md)).
|
||
The dev path (OpenTofu → Proxmox VM → cloud-init) **does not apply**: there is no hypervisor API to
|
||
call. Stage 1 "Create" is a human imaging a box. Stages 2–4 (baseline, cluster-join, manage) reuse
|
||
the *same* Ansible roles and the *same* Flux base as dev — that reuse is the R-ENV-02 obligation.
|
||
|
||
---
|
||
|
||
## 0. Node inventory
|
||
|
||
Fill a row per node as it lands. Node 1 is as-found on 2026-08-31.
|
||
|
||
| | node 1 | node 2 | node 3 |
|
||
|---|---|---|---|
|
||
| Hostname | `k3s-prod-1` | `k3s-prod-2` | `k3s-prod-3` |
|
||
| LAN IP | `192.168.2.10` | — | — |
|
||
| Model | HP EliteDesk 800 G5 Desktop Mini | | |
|
||
| CPU | i7-9700T, 8c/8t, VT-x | | |
|
||
| RAM | 31 GiB | | |
|
||
| Disks | 1× 477 GB SATA SSD (`C400-MTFDDAC512M`) | | |
|
||
| OS | Debian 13 (trixie), kernel 6.12 | | |
|
||
| Firmware | HP R21 Ver. 02.26.00 | | |
|
||
| `/dev/kvm` | present | | |
|
||
|
||
Dev nodes for comparison: 8 vCPU / 24 GiB / Debian 13, **two** dedicated data disks (Longhorn + etcd).
|
||
|
||
---
|
||
|
||
## 1. Firmware / BIOS (per node, before OS install)
|
||
|
||
- [ ] **Virtualization enabled** — VT-x *and* VT-d. Required for KubeVirt (R-PLAT-03); verify after
|
||
boot with `/dev/kvm` present and `grep -cE 'vmx|svm' /proc/cpuinfo` non-zero.
|
||
- [ ] **AC power recovery = Power On.** A homelab node must return after a power cut without a
|
||
human pressing the button. (`docs/02` calls out wake/boot behaviour explicitly.)
|
||
- [ ] **Wake-on-LAN enabled** on the onboard NIC (remote recovery when the box is off).
|
||
- [ ] **Boot order** — internal disk first; USB above it only while imaging. Disable network boot
|
||
unless PXE is adopted.
|
||
- [ ] **Secure Boot** — record the setting. k3s itself is fine either way; note it so all three
|
||
nodes match.
|
||
- [ ] **Firmware version recorded** in §0 and consistent across all three nodes.
|
||
|
||
## 2. Disk layout — **OPEN DECISION, blocks the build**
|
||
|
||
`docs/02` requires the OS-vs-Longhorn device split to be **documented before prod build**. Dev went
|
||
further and added a *third* device for etcd after HDD contention starved etcd WAL fsync
|
||
(`docs/plans/ssd-etcd-isolation.md`).
|
||
|
||
Node 1 as-found is a **single** 477 GB SATA SSD carrying everything:
|
||
|
||
```
|
||
sda 477G C400-MTFDDAC512M (SSD, ~2011-era Micron/Crucial)
|
||
├─sda1 976M /boot/efi
|
||
├─sda2 30G /
|
||
├─sda3 12G /var
|
||
├─sda4 977M swap
|
||
└─sda5 433G /srv <- the only large free space
|
||
```
|
||
|
||
Consequences to settle before imaging nodes 2 and 3:
|
||
|
||
- [ ] **Drive health checked first** (operator decision, 2026-08-31). See §5 for the command —
|
||
needs root. A ~15-year-old consumer SSD is not an obvious place for prod state.
|
||
- [ ] **Decide the layout.** `roles/node_baseline` expects *block devices*
|
||
(`node_baseline_longhorn_device`, `node_baseline_etcd_device`) and makes a filesystem on them.
|
||
Its defaults `/dev/vdb` and `/dev/vdc` are **virtio names that do not exist on bare metal** —
|
||
prod must override them in `group_vars`. On a single-disk node there is no second device at
|
||
all, so one of:
|
||
- **Add a second drive** (M.2 NVMe if the chassis has a free slot; verify physically — only a
|
||
SATA controller is populated today). Cleanest: matches dev's isolation, gives etcd its own
|
||
spindle.
|
||
- **Use `/dev/sda5`** (the 433 GB `/srv` partition) as the Longhorn device, etcd stays on `/`.
|
||
Buildable today, zero spend, but re-creates the shared-spindle contention dev was burned by.
|
||
- **Repartition** into dedicated OS / etcd / Longhorn partitions. Better isolation, still one
|
||
physical failure domain.
|
||
- [ ] **All three nodes get the identical layout.** Longhorn replica placement assumes symmetry.
|
||
- [ ] Record the chosen device paths here and set them in `inventory/group_vars/k3s_prod.yml`.
|
||
|
||
## 3. OS install (per node)
|
||
|
||
- [ ] **Debian 13 (trixie)**, matching dev exactly — same kernel series, same package baseline.
|
||
- [ ] Hostname `k3s-prod-N`.
|
||
- [ ] Partition per the §2 decision.
|
||
- [ ] **No cloud-init needed.** Dev's first-boot work was deliberately moved into
|
||
`roles/node_baseline` when provisioning became API-only (`infra/cloud-init/` is a README now),
|
||
so the same role covers bare metal. Nothing to port.
|
||
|
||
## 4. Network (per node)
|
||
|
||
- [ ] **Static IP** on the prod LAN, recorded in §0. Node 1 is `192.168.2.10/24`, gateway
|
||
`192.168.2.1`.
|
||
- [ ] **Reserve the VIP addresses** before the build — prod needs its own kube-vip control-plane VIP
|
||
*and* its own Cilium L2 announcement pool for ingress. Neither exists yet (§7).
|
||
- [ ] **Resolver: configure at least two upstreams.** Node 1 currently has a single IPv4 nameserver
|
||
(`192.168.2.1`). A single upstream is a known SPOF that has already bitten this project —
|
||
it broke containerd image pulls and CoreDNS forwarding on dev. A fix exists but is **stranded
|
||
unmerged** on `fix/node-dns-resilient-upstream`; land it, then apply the same pattern here.
|
||
- [ ] Confirm the prod LAN's relationship to the dev LAN (`192.168.1.x`) and to the pfSense NAT —
|
||
prod on `192.168.2.x` sits on the *workstation* side of the boundary dev lives behind.
|
||
|
||
## 5. Access (per node) — **blocks all Ansible**
|
||
|
||
- [ ] **`k3s` user with the `home_network` SSH key.** Working on node 1.
|
||
- [ ] **Password-protected sudo, driven by Ansible `become` + a vaulted password.**
|
||
**Prod does NOT use NOPASSWD sudo** (operator decision, 2026-08-31). Dev nodes do; prod
|
||
deliberately keeps the sudo password in place and supplies it to Ansible as an
|
||
**ansible-vault-encrypted** var, exactly like the existing `hypervisor` and `proxmox_hosts`
|
||
groups:
|
||
```
|
||
inventory/group_vars/k3s_prod/
|
||
README.md how to (re)create the vault — committed
|
||
vault.yml ansible_become_password: "..." — committed, ENCRYPTED
|
||
```
|
||
The passphrase that decrypts it lives **outside the repo** at
|
||
`~/.config/home-k3s/ansible-vault-pass` (`ansible.cfg :: vault_password_file`), so plays still
|
||
run unattended without a plaintext secret ever touching git.
|
||
```bash
|
||
ansible-vault create inventory/group_vars/k3s_prod/vault.yml # ansible_become_password: ...
|
||
```
|
||
Prod nodes must therefore set `ansible_become: true` in their group_vars and must **not**
|
||
inherit any passwordless-sudo assumption from `group_vars/all.yml`.
|
||
- [ ] **Drive health baseline** (§2), needs root:
|
||
```bash
|
||
sudo apt-get update && sudo apt-get install -y smartmontools
|
||
sudo smartctl -a /dev/sda # Power_On_Hours, Percent_Lifetime_Remaining, reallocated sectors
|
||
```
|
||
|
||
## 6. Ansible baseline & cluster join
|
||
|
||
Reuses the dev roles unchanged — that reuse **is** R-ENV-02. Only inventory and group_vars differ.
|
||
|
||
- [ ] Add a `k3s_prod` inventory group (`k3s_prod_primary` / `k3s_prod_secondary`). Prod is reached
|
||
**directly** on the LAN — no NAT port-forward hop, unlike dev's `192.168.2.102:225x` mapping.
|
||
- [ ] `group_vars/k3s_prod.yml`: `kube_vip_address`, `cluster_controller_api_server`, and the §2
|
||
device overrides for `node_baseline_longhorn_device` / `node_baseline_etcd_device`.
|
||
- [ ] Run `playbooks/node-baseline.yml` → packages, kernel modules, sysctls, iscsid, data-disk
|
||
filesystems + mounts. (`qemu-guest-agent` is a no-op on bare metal — the role already only
|
||
*starts* it when the virtio channel exists, so it degrades cleanly.)
|
||
- [ ] Run `playbooks/k3s.yml` → HA embedded etcd, flannel/kube-proxy/Traefik/servicelb disabled.
|
||
**Only once all three nodes are present** — see §8.
|
||
- [ ] Run `playbooks/kube-vip.yml` → control-plane VIP on the prod LAN.
|
||
- [ ] Run `playbooks/cilium.yml` → CNI at bootstrap; Flux's HelmRelease adopts it afterwards. The
|
||
bootstrap values and the HelmRelease **must stay in parity** (`kubeProxyReplacement`,
|
||
`k8sServiceHost`/`Port`) or the two layers fight over CNI config (`docs/02`).
|
||
- [ ] Decide whether prod runs a VPN egress gateway node (dev uses `k3s-dev-3`, ADR-0015).
|
||
|
||
## 7. Repo blockers — **prod cannot be reconciled until these land**
|
||
|
||
`clusters/prod` is design-only today and **would build wrong**. R-ENV-02 promises dev and prod differ
|
||
*only* by `cluster-vars` values; in practice dev LAN addresses are hardcoded into base manifests:
|
||
|
||
| Hardcoded value | Where | Prod needs |
|
||
|---|---|---|
|
||
| `k8sServiceHost: 192.168.1.50` | `platform/cilium/helmrelease.yaml:50`, mirrored in `values.yaml:16` | prod primary node IP |
|
||
| LB pool `192.168.1.53–.60` | `platform-config/cilium/l2-ip-pool.yaml:15` | a prod-LAN pool |
|
||
| `192.168.1.55` (crafty) | `platform/crafty/service-l4.yaml` | prod-LAN address |
|
||
| `192.168.1.54` (UniFi VM) | `apps/vms/unifi/50-service-l4.yaml` | prod-LAN address |
|
||
| `192.168.1.9:9000` (S3 backup) | `platform/keycloak/postgres-cluster.yaml`, `apps/wave-0/{nextcloud,semaphore}-db.yaml` | reachable prod backup target |
|
||
|
||
- [ ] **Tokenize each into a `cluster-vars` knob** with a base default, then set the value in *both*
|
||
overlays. Adding a knob before referencing `${KNOB}` is the sanctioned mechanism (see the
|
||
header comment in `clusters/base/cluster-vars.yaml`). `platform`, `platform-config`, the app
|
||
waves, `apps-vms` and `crafty` all already carry `postBuild.substituteFrom: cluster-vars`, so
|
||
the seam exists.
|
||
- [ ] **`clusters/prod` must set `GATEWAY_VIP`.** It currently doesn't, so prod would inherit the
|
||
base default `10.73.0.240` — an address from the **retired libvirt network**. The base file's
|
||
own comment flags this as owed "when hardware is built."
|
||
- [ ] **Dev overlay sets every new knob to today's exact value** so rendered dev output is
|
||
byte-identical and the live cluster sees zero drift. Verify with `make -C ci render-golden`.
|
||
- [ ] Confirm prod's backup target: dev's S3 (`versitygw` on the Proxmox host, `192.168.1.9`) is on
|
||
the dev side of the network. Off-cluster backup is DR-critical (R-STATE-03).
|
||
|
||
## 8. Build sequence (operator decision, 2026-08-31: **wait for all three nodes**)
|
||
|
||
Node 1 is baselined now; the cluster is **not** initialized until nodes 2 and 3 are on the bench.
|
||
This keeps prod spec-conformant (3-node HA embedded etcd) from its first boot, avoids a
|
||
single-server-etcd window, and avoids a later member-add dance.
|
||
|
||
1. Per-node §1–§5 on each of the three boxes.
|
||
2. §7 repo work lands on `main` with the gate green.
|
||
3. `node-baseline` → `k3s` (all three) → `kube-vip` → `cilium`.
|
||
4. `flux bootstrap ... --path=clusters/prod`.
|
||
5. Conformance against prod (§9).
|
||
|
||
## 9. Exit criteria (Phase 7)
|
||
|
||
- [ ] Prod runs the same config as dev via the prod overlay, **no base edits** (R-ENV-02).
|
||
- [ ] Node destroy/rebuild from IaC + Ansible without data loss (R-ENV-01, R-STATE-01).
|
||
- [ ] Full **automated** prod DR drill (R-STATE-03) — `definition-of-done.md` requires this for prod
|
||
specifically.
|
||
- [ ] Monitoring and alerts live on prod.
|
||
- [ ] The conformance suite passes green **against the prod cluster**, not just dev (R-TEST-03).
|