jakman85andClaude Opus 5
a1fb31a7ef
PROD-PROVISIONING.md §4 now carries the full operator-decided address table (nodes .10/.11/.12, control-plane VIP .9, ingress Gateway VIP .20, Cilium LB pool .20-.30) with the two invariants that make it safe: the control-plane VIP sits outside the LB pool so kube-vip and LB-IPAM cannot contend, and GATEWAY_VIP is the FIRST address of the pool because the shared Gateway pins nothing and LB-IPAM hands it the first free address. §5 no longer tells the operator to hand-install smartmontools — package installation is the node_baseline role's job (operator ruling). §0 gains the node 2/3 addresses. Task: T-7.1. Gate: MERGE GATE: PASS. Co-Authored-By: Claude Opus 5 (1M context) <[email protected]>
222 lines
13 KiB
Markdown
222 lines
13 KiB
Markdown
# Prod bare-metal provisioning checklist (T-7.1)
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**Task:** T-7.1 · **Workstream:** WS-INFRA · **Serves:** R-ENV-01, R-ENV-02, R-ENV-03, R-PLAT-01/03
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**Status:** Phase 7 **opened by the operator 2026-08-31** — *prep only*. Nothing is installed on prod
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hardware until the blockers in §7 are closed and `make -C ci gate` is green.
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> **Entry-gate note (recorded, not waived).** `roadmap/phases.md` gates Phase 7 on *"Phases 1–6
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> proven in dev/test; operator declares prod hardware ready."* The operator has declared hardware
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> ready. The first condition is **not** met: conformance is 37/51, and the uncovered set includes
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> **R-ENV-01/02/03** — the very requirements this document serves. We proceed with prep work
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> knowingly; see `DECISIONS-LOG.md` (2026-08-31 Phase-7 entry).
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Prod is **3× mini-PC bare metal** ([spec docs/02](../../home-network-k3s/docs/02-environments-and-provisioning.md)).
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The dev path (OpenTofu → Proxmox VM → cloud-init) **does not apply**: there is no hypervisor API to
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call. Stage 1 "Create" is a human imaging a box. Stages 2–4 (baseline, cluster-join, manage) reuse
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the *same* Ansible roles and the *same* Flux base as dev — that reuse is the R-ENV-02 obligation.
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---
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## 0. Node inventory
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Fill a row per node as it lands. Node 1 is as-found on 2026-08-31.
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| | node 1 | node 2 | node 3 |
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|---|---|---|---|
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| Hostname | `k3s-prod-1` | `k3s-prod-2` | `k3s-prod-3` |
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| LAN IP | `192.168.2.10` | `192.168.2.11` | `192.168.2.12` |
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| Model | HP EliteDesk 800 G5 Desktop Mini | | |
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| CPU | i7-9700T, 8c/8t, VT-x | | |
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| RAM | 31 GiB | | |
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| Disks | 1× 477 GB SATA SSD (`C400-MTFDDAC512M`) | | |
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| OS | Debian 13 (trixie), kernel 6.12 | | |
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| Firmware | HP R21 Ver. 02.26.00 | | |
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| `/dev/kvm` | present | | |
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Dev nodes for comparison: 8 vCPU / 24 GiB / Debian 13, **two** dedicated data disks (Longhorn + etcd).
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---
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## 1. Firmware / BIOS (per node, before OS install)
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- [ ] **Virtualization enabled** — VT-x *and* VT-d. Required for KubeVirt (R-PLAT-03); verify after
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boot with `/dev/kvm` present and `grep -cE 'vmx|svm' /proc/cpuinfo` non-zero.
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- [ ] **AC power recovery = Power On.** A homelab node must return after a power cut without a
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human pressing the button. (`docs/02` calls out wake/boot behaviour explicitly.)
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- [ ] **Wake-on-LAN enabled** on the onboard NIC (remote recovery when the box is off).
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- [ ] **Boot order** — internal disk first; USB above it only while imaging. Disable network boot
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unless PXE is adopted.
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- [ ] **Secure Boot** — record the setting. k3s itself is fine either way; note it so all three
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nodes match.
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- [ ] **Firmware version recorded** in §0 and consistent across all three nodes.
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## 2. Disk layout — **OPEN DECISION, blocks the build**
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`docs/02` requires the OS-vs-Longhorn device split to be **documented before prod build**. Dev went
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further and added a *third* device for etcd after HDD contention starved etcd WAL fsync
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(`docs/plans/ssd-etcd-isolation.md`).
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Node 1 as-found is a **single** 477 GB SATA SSD carrying everything:
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```
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sda 477G C400-MTFDDAC512M (SSD, ~2011-era Micron/Crucial)
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├─sda1 976M /boot/efi
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├─sda2 30G /
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├─sda3 12G /var
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├─sda4 977M swap
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└─sda5 433G /srv <- the only large free space
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```
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Consequences to settle before imaging nodes 2 and 3:
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- [ ] **Drive health checked first** (operator decision, 2026-08-31). See §5 for the command —
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needs root. A ~15-year-old consumer SSD is not an obvious place for prod state.
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- [ ] **Decide the layout.** `roles/node_baseline` expects *block devices*
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(`node_baseline_longhorn_device`, `node_baseline_etcd_device`) and makes a filesystem on them.
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Its defaults `/dev/vdb` and `/dev/vdc` are **virtio names that do not exist on bare metal** —
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prod must override them in `group_vars`. On a single-disk node there is no second device at
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all, so one of:
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- **Add a second drive** (M.2 NVMe if the chassis has a free slot; verify physically — only a
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SATA controller is populated today). Cleanest: matches dev's isolation, gives etcd its own
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spindle.
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- **Use `/dev/sda5`** (the 433 GB `/srv` partition) as the Longhorn device, etcd stays on `/`.
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Buildable today, zero spend, but re-creates the shared-spindle contention dev was burned by.
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- **Repartition** into dedicated OS / etcd / Longhorn partitions. Better isolation, still one
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physical failure domain.
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- [ ] **All three nodes get the identical layout.** Longhorn replica placement assumes symmetry.
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- [ ] Record the chosen device paths here and set them in `inventory/group_vars/k3s_prod.yml`.
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## 3. OS install (per node)
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- [ ] **Debian 13 (trixie)**, matching dev exactly — same kernel series, same package baseline.
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- [ ] Hostname `k3s-prod-N`.
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- [ ] Partition per the §2 decision.
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- [ ] **No cloud-init needed.** Dev's first-boot work was deliberately moved into
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`roles/node_baseline` when provisioning became API-only (`infra/cloud-init/` is a README now),
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so the same role covers bare metal. Nothing to port.
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## 4. Network (per node)
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- [ ] **Static IP** on the prod LAN, recorded in §0. Node 1 is `192.168.2.10/24`, gateway
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`192.168.2.1`.
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- [x] **Prod address plan — DECIDED (operator, 2026-08-31).**
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| Role | Address | Owned by |
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|---|---|---|
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| `k3s-prod-1` / `-2` / `-3` | `192.168.2.10` / `.11` / `.12` | Ansible inventory |
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| **kube-vip control-plane VIP** | `192.168.2.9` | Ansible (`group_vars/k3s_prod`) |
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| **Ingress Gateway VIP** (`GATEWAY_VIP`) | `192.168.2.20` | Flux (`clusters/prod`) |
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| **Cilium L2 announcement pool** | `192.168.2.20` – `.30` | Flux (`platform-config/cilium`) |
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Two deliberate properties, both mirroring dev:
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- The **control-plane VIP sits outside the LB pool** (`.9`, below the nodes), so kube-vip and
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Cilium LB-IPAM can never contend for the same address. Dev achieves this the other way
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round (`.49` control-plane, pool `.53-.60`).
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- **`GATEWAY_VIP` is the FIRST address of the pool.** Cilium LB-IPAM can only allocate from a
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defined pool block, so a Gateway VIP outside every pool would not be allocatable — the pool
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was widened from `.21-.30` to `.20-.30` for exactly this reason. Dev has the same shape
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(`GATEWAY_VIP` `.53` = first of `.53-.60`).
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- [ ] **Reserve all of `192.168.2.9` and `.20-.30` outside any DHCP range** on the prod LAN before
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the build, and confirm nothing else on the network already answers on them.
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- [ ] **Resolver: configure at least two upstreams.** Node 1 currently has a single IPv4 nameserver
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(`192.168.2.1`). A single upstream is a known SPOF that has already bitten this project —
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it broke containerd image pulls and CoreDNS forwarding on dev. A fix exists but is **stranded
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unmerged** on `fix/node-dns-resilient-upstream`; land it, then apply the same pattern here.
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- [ ] Confirm the prod LAN's relationship to the dev LAN (`192.168.1.x`) and to the pfSense NAT —
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prod on `192.168.2.x` sits on the *workstation* side of the boundary dev lives behind.
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## 5. Access (per node) — **blocks all Ansible**
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- [ ] **`k3s` user with the `home_network` SSH key.** Working on node 1.
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- [ ] **Password-protected sudo, driven by Ansible `become` + a vaulted password.**
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**Prod does NOT use NOPASSWD sudo** (operator decision, 2026-08-31). Dev nodes do; prod
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deliberately keeps the sudo password in place and supplies it to Ansible as an
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**ansible-vault-encrypted** var, exactly like the existing `hypervisor` and `proxmox_hosts`
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groups:
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```
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inventory/group_vars/k3s_prod/
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README.md how to (re)create the vault — committed
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vault.yml ansible_become_password: "..." — committed, ENCRYPTED
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```
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The passphrase that decrypts it lives **outside the repo** at
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`~/.config/home-k3s/ansible-vault-pass` (`ansible.cfg :: vault_password_file`), so plays still
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run unattended without a plaintext secret ever touching git.
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```bash
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ansible-vault create inventory/group_vars/k3s_prod/vault.yml # ansible_become_password: ...
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```
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Prod nodes must therefore set `ansible_become: true` in their group_vars and must **not**
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inherit any passwordless-sudo assumption from `group_vars/all.yml`.
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- [ ] **Drive health baseline** (§2). **Do not hand-install the tooling** — package installation is
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the `node_baseline` role's job, never a manual `apt-get` on a node (operator ruling,
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2026-08-31; same click-ops-never principle as the rest of the repo). `smartmontools` is part
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of `node_baseline_packages`, so it arrives with the baseline play. Reading the drive is then:
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```bash
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sudo smartctl -a /dev/sda # Power_On_Hours, Percent_Lifetime_Remaining, reallocated sectors
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```
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## 6. Ansible baseline & cluster join
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Reuses the dev roles unchanged — that reuse **is** R-ENV-02. Only inventory and group_vars differ.
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- [ ] Add a `k3s_prod` inventory group (`k3s_prod_primary` / `k3s_prod_secondary`). Prod is reached
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**directly** on the LAN — no NAT port-forward hop, unlike dev's `192.168.2.102:225x` mapping.
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- [ ] `group_vars/k3s_prod.yml`: `kube_vip_address`, `cluster_controller_api_server`, and the §2
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device overrides for `node_baseline_longhorn_device` / `node_baseline_etcd_device`.
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- [ ] Run `playbooks/node-baseline.yml` → packages, kernel modules, sysctls, iscsid, data-disk
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filesystems + mounts. (`qemu-guest-agent` is a no-op on bare metal — the role already only
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*starts* it when the virtio channel exists, so it degrades cleanly.)
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- [ ] Run `playbooks/k3s.yml` → HA embedded etcd, flannel/kube-proxy/Traefik/servicelb disabled.
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**Only once all three nodes are present** — see §8.
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- [ ] Run `playbooks/kube-vip.yml` → control-plane VIP on the prod LAN.
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- [ ] Run `playbooks/cilium.yml` → CNI at bootstrap; Flux's HelmRelease adopts it afterwards. The
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bootstrap values and the HelmRelease **must stay in parity** (`kubeProxyReplacement`,
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`k8sServiceHost`/`Port`) or the two layers fight over CNI config (`docs/02`).
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- [ ] Decide whether prod runs a VPN egress gateway node (dev uses `k3s-dev-3`, ADR-0015).
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## 7. Repo blockers — **prod cannot be reconciled until these land**
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`clusters/prod` is design-only today and **would build wrong**. R-ENV-02 promises dev and prod differ
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*only* by `cluster-vars` values; in practice dev LAN addresses are hardcoded into base manifests:
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| Hardcoded value | Where | Prod needs |
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|---|---|---|
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| `k8sServiceHost: 192.168.1.50` | `platform/cilium/helmrelease.yaml:50`, mirrored in `values.yaml:16` | prod primary node IP |
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| LB pool `192.168.1.53–.60` | `platform-config/cilium/l2-ip-pool.yaml:15` | a prod-LAN pool |
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| `192.168.1.55` (crafty) | `platform/crafty/service-l4.yaml` | prod-LAN address |
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| `192.168.1.54` (UniFi VM) | `apps/vms/unifi/50-service-l4.yaml` | prod-LAN address |
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| `192.168.1.9:9000` (S3 backup) | `platform/keycloak/postgres-cluster.yaml`, `apps/wave-0/{nextcloud,semaphore}-db.yaml` | reachable prod backup target |
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- [ ] **Tokenize each into a `cluster-vars` knob** with a base default, then set the value in *both*
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overlays. Adding a knob before referencing `${KNOB}` is the sanctioned mechanism (see the
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header comment in `clusters/base/cluster-vars.yaml`). `platform`, `platform-config`, the app
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waves, `apps-vms` and `crafty` all already carry `postBuild.substituteFrom: cluster-vars`, so
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the seam exists.
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- [ ] **`clusters/prod` must set `GATEWAY_VIP`.** It currently doesn't, so prod would inherit the
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base default `10.73.0.240` — an address from the **retired libvirt network**. The base file's
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own comment flags this as owed "when hardware is built."
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- [ ] **Dev overlay sets every new knob to today's exact value** so rendered dev output is
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byte-identical and the live cluster sees zero drift. Verify with `make -C ci render-golden`.
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- [ ] Confirm prod's backup target: dev's S3 (`versitygw` on the Proxmox host, `192.168.1.9`) is on
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the dev side of the network. Off-cluster backup is DR-critical (R-STATE-03).
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## 8. Build sequence (operator decision, 2026-08-31: **wait for all three nodes**)
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Node 1 is baselined now; the cluster is **not** initialized until nodes 2 and 3 are on the bench.
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This keeps prod spec-conformant (3-node HA embedded etcd) from its first boot, avoids a
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single-server-etcd window, and avoids a later member-add dance.
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1. Per-node §1–§5 on each of the three boxes.
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2. §7 repo work lands on `main` with the gate green.
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3. `node-baseline` → `k3s` (all three) → `kube-vip` → `cilium`.
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4. `flux bootstrap ... --path=clusters/prod`.
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5. Conformance against prod (§9).
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## 9. Exit criteria (Phase 7)
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- [ ] Prod runs the same config as dev via the prod overlay, **no base edits** (R-ENV-02).
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- [ ] Node destroy/rebuild from IaC + Ansible without data loss (R-ENV-01, R-STATE-01).
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- [ ] Full **automated** prod DR drill (R-STATE-03) — `definition-of-done.md` requires this for prod
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specifically.
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- [ ] Monitoring and alerts live on prod.
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- [ ] The conformance suite passes green **against the prod cluster**, not just dev (R-TEST-03).
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