home-network-k3s-impl/clusters/prod/kustomization.yaml

---
# clusters/prod — DESIGN-ONLY overlay. NOT a build target until roadmap Phase 7 opens prod
# (spec roadmap/phases.md, AGENTS.md §6: "Never build directly on production").
#
# When Phase 7 is opened, `flux bootstrap ... --path=clusters/prod` points the prod cluster's Flux
# here. Like dev, this overlay adds NO resources — it ONLY patches cluster-vars with prod-scoped
# values (R-ENV-02). Promotion to prod is a change to THESE variables, never a base edit.
#
# *** PHASE-7 BLOCKER — READ BEFORE BOOTSTRAPPING PROD ***
# `clusters/base/platform.yaml` now carries `dependsOn: [flux-system]` (the 2026-09-01 substitution-
# race fix). That names the ROOT Kustomization, which clusters/dev supplies as `dev/sync.yaml`
# (path ./clusters/dev). THIS overlay has no sync.yaml yet, so as written a prod bootstrap would
# leave `platform` stuck on "dependency 'flux-system/flux-system' is not ready" FOREVER and nothing
# downstream would reconcile. Phase 7 MUST add `clusters/prod/sync.yaml` — a copy of dev/sync.yaml
# with `path: ./clusters/prod` — as part of opening this overlay. (Adding it now is deliberately NOT
# done here: prod is design-only and its root object is the prod bring-up owner's call.)
apiVersion: kustomize.config.k8s.io/v1beta1
kind: Kustomization
resources:
  - ../base
  - sync.yaml          # self-managing root Kustomization -> ./clusters/prod (REQUIRED: see below)
patches:
  # --- SOPS decryption (operator decision 2026-09-01: prod uses the SAME age key as dev) ---
  # Mirrors clusters/dev exactly, one stanza per Kustomization that carries encrypted Secrets.
  # The `sops-age` Secret is created OUT OF BAND on the prod cluster
  # (bootstrap/sops/install-age-key.sh) — referenced by NAME only, never inlined.
  # Add a stanza here whenever `render.py --emit-waves` introduces a new deepest wave.
  - patch: |-
      apiVersion: kustomize.toolkit.fluxcd.io/v1
      kind: Kustomization
      metadata:
        name: platform
        namespace: flux-system
      spec:
        decryption:
          provider: sops
          secretRef:
            name: sops-age
  - patch: |-
      apiVersion: kustomize.toolkit.fluxcd.io/v1
      kind: Kustomization
      metadata:
        name: apps-wave-0
        namespace: flux-system
      spec:
        decryption:
          provider: sops
          secretRef:
            name: sops-age
  - patch: |-
      apiVersion: kustomize.toolkit.fluxcd.io/v1
      kind: Kustomization
      metadata:
        name: apps-wave-1
        namespace: flux-system
      spec:
        decryption:
          provider: sops
          secretRef:
            name: sops-age
  - patch: |-
      apiVersion: kustomize.toolkit.fluxcd.io/v1
      kind: Kustomization
      metadata:
        name: apps-wave-2
        namespace: flux-system
      spec:
        decryption:
          provider: sops
          secretRef:
            name: sops-age
  - patch: |-
      apiVersion: kustomize.toolkit.fluxcd.io/v1
      kind: Kustomization
      metadata:
        name: oauth2-proxy
        namespace: flux-system
      spec:
        decryption:
          provider: sops
          secretRef:
            name: sops-age
  - patch: |-
      apiVersion: kustomize.toolkit.fluxcd.io/v1
      kind: Kustomization
      metadata:
        name: headlamp
        namespace: flux-system
      spec:
        decryption:
          provider: sops
          secretRef:
            name: sops-age
  - patch: |-
      apiVersion: kustomize.toolkit.fluxcd.io/v1
      kind: Kustomization
      metadata:
        name: crafty
        namespace: flux-system
      spec:
        decryption:
          provider: sops
          secretRef:
            name: sops-age
  - patch: |-
      apiVersion: kustomize.toolkit.fluxcd.io/v1
      kind: Kustomization
      metadata:
        name: velero
        namespace: flux-system
      spec:
        decryption:
          provider: sops
          secretRef:
            name: sops-age
  # --- GitOps source (operator decision 2026-09-01: prod tracks the SAME BRANCH as dev) ---
  #
  # ############################################################################################
  # ###                                                                                      ###
  # ###   *** T E M P O R A R Y   B O O T S T R A P   S O U R C E  —  NOT PERMANENT ***       ###
  # ###                                                                                      ###
  # ###   The url below is a Gitea container running ON THE OPERATOR'S WORKSTATION, outside   ###
  # ###   any cluster. It exists ONLY to get prod's first reconcile off the ground. It MUST   ###
  # ###   be cut over to the in-cluster URL once Gitea runs on prod. If you are reading this  ###
  # ###   and prod has been serving traffic for months, THE CUTOVER WAS NEVER DONE — that is  ###
  # ###   a live single point of failure, not a settled design. See "CUTOVER" below.          ###
  # ###                                                                                      ###
  # ############################################################################################
  #
  # WHY THE IN-CLUSTER URL CANNOT BE USED YET (blocker found 2026-09-01, still true; the
  # unusable value was `https://gitea.home.keithjackson.dev/Home-Network/home-network-k3s-impl.git`).
  # Two independent reasons, both consequences of the split-horizon design:
  #   1. SELF-HOSTING CIRCULARITY. Gitea runs ON THE DEV CLUSTER. Prod syncing from it means prod's
  #      GitOps source lives inside the very cluster slated for decommission. Gitea must move to
  #      prod (or off-cluster) BEFORE dev is retired, or prod loses its source of truth.
  #   2. SPLIT-HORIZON DNS SENDS IT TO THE WRONG PLACE. platform/coredns/coredns-custom.yaml
  #      answers the ENTIRE home.keithjackson.dev zone with ${GATEWAY_VIP}. On prod that is
  #      192.168.2.20 — PROD's own gateway, where no Gitea is listening. Prod's Flux would resolve
  #      gitea.home.keithjackson.dev to itself and never reach a repository.
  #
  # WHAT THE TEMPORARY SOURCE IS (stood up 2026-09-04 on explicit operator direction):
  #   bootstrap/gitea/bootstrap-gitea.sh with HOST_NAT_IP=192.168.2.132 — a podman container on the
  #   operator's workstation, Gitea 1.22.6, listening on 192.168.2.132:3000. All three prod nodes
  #   reach it DIRECTLY on the LAN: no libvirt NAT hop (that network is retired) and no firewall
  #   change was needed. This is the same "local bootstrap source" pattern dev itself used before
  #   its Phase-6 cutover (docs/05 "Source-of-truth").
  #
  # PLAIN HTTP, AND WHY THAT IS ACCEPTED HERE: the bootstrap Gitea has no TLS, so there is no cert
  # for Flux to trust and no caCertSecretRef to wire. Traffic is LAN-local between prod nodes and
  # the workstation, the repo carries NO plaintext secrets (everything sensitive is SOPS-encrypted,
  # .sops.yaml), and the window is the bring-up only. Do NOT extend this posture past cutover.
  #
  # NO secretRef, DELIBERATELY: the repo is PUBLIC on the bootstrap Gitea, so anonymous clone
  # works and Flux needs no git credentials. VERIFIED 2026-09-04 by unauthenticated request:
  #   curl http://192.168.2.132:3000/api/v1/repos/Home-Network/home-network-k3s-impl -> "private":false
  #   git ls-remote http://192.168.2.132:3000/Home-Network/home-network-k3s-impl.git  -> refs/heads/main
  # If the GitRepository ever reports an auth failure that looks like a network problem, RE-CHECK
  # THAT FIRST: a private repo here fails exactly that way.
  #
  # *** CUTOVER — the exit condition, mirroring dev's Phase-6 cutover (docs/05) ***
  #   WHEN: Gitea runs on prod (reconciled in-cluster) and answers gitea.home.keithjackson.dev
  #         through prod's own Gateway VIP with a publicly-trusted cert.
  #   DO:   1. push/mirror this repo into the prod in-cluster Gitea;
  #         2. change the url below to
  #            https://gitea.home.keithjackson.dev/Home-Network/home-network-k3s-impl.git
  #            and DELETE this whole TEMPORARY block (dev's equivalent stanza, ~15 lines above in
  #            clusters/dev/kustomization.yaml, is what "done" looks like);
  #         3. confirm `flux get sources git -n flux-system` reconciles the new revision;
  #         4. only THEN stop the workstation container. Keep it stopped-not-deleted as recovery,
  #            exactly as dev retained its bootstrap Gitea.
  #   UNTIL THEN: prod's reconciliation depends on a container on a workstation that may be
  #   powered off. Flux keeps the last-reconciled state running, but NO new revision lands while
  #   it is down. Tracked as an open blocker in infra/PROD-PROVISIONING.md §7.
  #
  # The BRANCH below is settled and correct: prod tracks `main`, the same branch as dev.
  # CONSEQUENCE, recorded deliberately: once prod is live, EVERY MERGE TO main RECONCILES BOTH
  # CLUSTERS. There is no promotion step and no soak window — dev and prod move together.
  # NOTE for bring-up: bootstrap-gitea.sh pushes the operator's CURRENT HEAD to the bootstrap
  # Gitea's `main`, whatever branch that is. Before bootstrapping prod, confirm that remote `main`
  # is the revision you intend prod to run (`git ls-remote` above, against local `main`).
  - patch: |-
      apiVersion: source.toolkit.fluxcd.io/v1
      kind: GitRepository
      metadata:
        name: flux-system
        namespace: flux-system
      spec:
        # TEMPORARY bootstrap source — workstation container, NOT in any cluster. See the block
        # above for the cutover to https://gitea.home.keithjackson.dev/... . Do not treat as final.
        url: http://192.168.2.132:3000/Home-Network/home-network-k3s-impl.git
        ref:
          branch: main
  - target:
      kind: ConfigMap
      name: cluster-vars
    patch: |-
      - op: replace
        path: /data/CLUSTER_ENV
        value: "prod"
      # trusted, rate-limited real certs in prod — ADR-0006.
      - op: replace
        path: /data/ACME_CLUSTER_ISSUER
        value: "letsencrypt-prod"
      # ==========================================================================================
      # PROD DNS IDENTITY (R-DNS-01/02/03) — the fix for the 2026-09-04 incident.
      # ==========================================================================================
      # PROD SERVES ITS OWN SUBDOMAIN. Until 2026-09-04 every hostname was HARDCODED to
      # home.keithjackson.dev in the base manifests, so prod was authored to serve the EXACT SAME
      # public names as the live dev cluster out of the SAME Cloudflare zone. Two consequences, one
      # of which already happened:
      #   1. HAPPENED: prod's external-dns (policy: sync, owner id `default` — the same implicit
      #      default dev had) concluded it owned dev's records and DELETED EVERY ONE of them.
      #   2. QUEUED BEHIND IT: platform-config would have requested a `*.home.keithjackson.dev`
      #      wildcard from letsencrypt-prod for a cert dev already holds, and both clusters would
      #      have raced each other's `_acme-challenge` TXT records on that one zone.
      # Moving prod to its own suffix dissolves both: the two clusters can no longer name the same
      # record. This is what makes ACME_CLUSTER_ISSUER: letsencrypt-prod above safe here.
      #
      #   dev   -> home.keithjackson.dev         (UNCHANGED — dev is live; phase 2 moves it)
      #   prod  -> prod.home.keithjackson.dev    (this knob)
      #
      # CONSEQUENCE — prod's hostnames are NOT the apex names. Prod's Gitea is
      # gitea.prod.home.keithjackson.dev, its Keycloak keycloak.prod.home.keithjackson.dev, and so
      # on; the wildcard cert becomes `*.prod.home.keithjackson.dev`. The apex CNAMEs that make
      # `<svc>.home.keithjackson.dev` point at prod are PHASE 2, deliberately not done here — they
      # would take traffic off the live dev cluster. infra/PROD-PROVISIONING.md §10.
      #
      # [parity] MUST equal k3s_base_domain in infra/ansible/inventory/group_vars/k3s_prod/vars.yml.
      # The kube-apiserver's oidc-issuer-url is an INSTALL-TIME k3s flag, not a manifest, so it is
      # set Ansible-side from that variable and cannot read this one. If they disagree, kubectl SSO
      # trusts a different Keycloak than the one prod actually runs.
      - op: replace
        path: /data/BASE_DOMAIN
        value: "prod.home.keithjackson.dev"
      # SAFETY NET #2 (independent of the owner id below): narrow ExternalDNS's name scope to prod's
      # OWN subtree, so prod cannot create, update or delete any record outside it no matter what the
      # TXT registry says. VERIFY ON FIRST RECONCILE — the Cloudflare provider uses this value for
      # ZONE selection too, and on the version in use in 2026-08 a strict-subdomain filter dropped
      # the parent zone ("no hosted zone matching record DNS Name"). If prod's external-dns logs no
      # matching zone, it will create NOTHING — fail-closed, and it can still never delete dev's
      # records. Fallback in that case: set this to "keithjackson.dev" (dev's value) and rely on
      # EXTERNALDNS_TXT_OWNER_ID below, which is sufficient on its own.
      - op: replace
        path: /data/EXTERNALDNS_DOMAIN_FILTER
        # MUST be the Cloudflare ZONE, not prod's subdomain. FINDING F-DNS1 (DECISIONS-LOG,
        # 2026-08-17) proved a subdomain filter DROPS THE PARENT ZONE: ExternalDNS generated the
        # record then skipped it with "no hosted zone matching record DNS Name", so prod would
        # publish NOTHING. Isolation from dev does NOT come from this filter — it comes from
        # (1) prod only requesting *.prod.home.keithjackson.dev hostnames, and
        # (2) txtOwnerId: prod, so prod's registry never claims dev's `default`-owned records.
        # That pairing is what the 2026-09-04 incident needed and this filter cannot provide.
        value: "keithjackson.dev"
      # SAFETY NET #1 — THE ACTUAL ROOT CAUSE OF THE INCIDENT. Both clusters left this unset and so
      # both inherited the chart default `default`; prod then treated dev's TXT-registry entries as
      # its own and, under policy: sync, deleted the records behind them. This value MUST differ from
      # dev's (`default`, pinned in clusters/dev — dev's live records are registered under it and
      # cannot be renamed without orphaning them). `prod` is distinct, which is the entire fix.
      - op: replace
        path: /data/EXTERNALDNS_TXT_OWNER_ID
        value: "prod"
      - op: replace
        path: /data/LONGHORN_DEFAULT_REPLICA_COUNT
        value: "3"
      # Longhorn's on-node replica directory: a SUBDIRECTORY of the claimed data partition, not
      # the mount root. Prod's ~424 GB partition (LABEL=k3s-data) is mounted at the neutral /data
      # and serves TWO tenants — /data/longhorn here, and /data/k3s for k3s's entire data dir
      # (embedded etcd + the containerd image store), which had to move off the 11.8 GiB /var:
      # measured on dev, containerd alone is 21-25 GB per node, so prod would have filled /var on
      # its first image pulls and etcd could not have written its WAL. infra/PROD-PROVISIONING.md §2.
      #
      # [parity] MUST equal node_baseline_longhorn_data_path in
      # infra/ansible/inventory/group_vars/k3s_prod/vars.yml — Ansible creates and mounts the
      # directory, this tells Longhorn to use it. If they disagree, Longhorn writes replicas to a
      # path on the OS filesystem instead of the data partition and /var fills up.
      - op: replace
        path: /data/LONGHORN_DATA_PATH
        value: "/data/longhorn"
      # longer retention / larger volumes on prod NVMe.
      - op: replace
        path: /data/MONITORING_PROMETHEUS_RETENTION
        value: "30d"
      - op: replace
        path: /data/MONITORING_PROMETHEUS_PVC_SIZE
        value: "50Gi"
      # Size-cap below the 50Gi PVC (headroom for WAL + head + compaction scratch): prod may hit the
      # size cap before 30d if series volume is high, keeping the disk from filling either way.
      - op: replace
        path: /data/MONITORING_PROMETHEUS_RETENTION_SIZE
        value: "45GiB"
      - op: replace
        path: /data/MONITORING_LOKI_PVC_SIZE
        value: "50Gi"
      # HA control-plane addons in prod.
      - op: replace
        path: /data/KEYCLOAK_REPLICAS
        value: "2"
      - op: replace
        path: /data/OAUTH2_PROXY_REPLICAS
        value: "2"
      - op: replace
        path: /data/VELERO_RETENTION
        value: "720h"
      # ==========================================================================================
      # PROD LAN ADDRESSING (192.168.2.0/24). Nodes: k3s-prod-1/2/3 = .10 / .11 / .12.
      # ==========================================================================================
      # These knobs were HARDCODED to the dev LAN inside base manifests until 2026-08-31; prod would
      # have come up ANNOUNCING DEV ADDRESSES (192.168.1.x) on the prod LAN. They are knobs now, and
      # this overlay supplies every one of them. Anything the operator has NOT yet decided stays an
      # INVALID `TBD-PROD-*` placeholder on purpose: base defaults are the DEV values, so an OMITTED
      # op means prod silently inherits a dev address — far worse than a failed apply. `TBD-PROD-*`
      # is not a valid IP/URL, so Cilium CRD validation / LB-IPAM / CNPG / Velero reject it LOUDLY.
      #
      # ------------------------------------------------------------------------------------------
      # ADDRESS PLAN (operator, 2026-08-31) — see infra/PROD-PROVISIONING.md §4 for the full table.
      # ------------------------------------------------------------------------------------------
      #   nodes                 192.168.2.10 / .11 / .12   (Ansible inventory)
      #   control-plane VIP     192.168.2.9                (Ansible group_vars/k3s_prod — NOT here)
      #   ingress Gateway VIP   192.168.2.20               (GATEWAY_VIP, below)
      #   Cilium LB pool        192.168.2.20 - .30         (CILIUM_LB_POOL_*, below)
      #
      # CONTAINMENT INVARIANT SATISFIED: GATEWAY_VIP (.20) IS CILIUM_LB_POOL_START, mirroring dev
      # (.53 of .53-.60). This matters because the `shared` Gateway (platform/gateway/gateway.yaml)
      # pins NOTHING — no `lbipam.cilium.io/ips`, no spec.addresses (unlike platform/crafty and
      # apps/vms/unifi, which DO pin) — so Cilium LB-IPAM assigns it the FIRST FREE address of a
      # matching pool block. Had GATEWAY_VIP stayed outside every pool (the original .21-.30
      # proposal), the Gateway would have come up on .21 while split-horizon coredns-custom kept
      # answering *.home.keithjackson.dev with .20 — an address nothing announces — blackholing
      # in-cluster hairpin traffic (OIDC clients -> Keycloak/Grafana) while looking healthy.
      # KEEP GATEWAY_VIP == CILIUM_LB_POOL_START when changing either.
      # The control-plane VIP (.9) is deliberately OUTSIDE this pool: kube-vip floats it, and
      # LB-IPAM must never be able to hand it to a Service.
      - op: replace
        path: /data/GATEWAY_VIP
        value: "192.168.2.20"
      # Cilium LB IP pool, operator-supplied: 192.168.2.20-.30 (START == GATEWAY_VIP, see above).
      # Mirror this range into the prod tofu reservation (cilium_l2_vip_range) if prod ever gets one.
      - op: replace
        path: /data/CILIUM_LB_POOL_START
        value: "192.168.2.20"
      - op: replace
        path: /data/CILIUM_LB_POOL_STOP
        value: "192.168.2.30"
      # --- still UNDECIDED -> loud placeholders (must be real before `flux bootstrap`) ------------
      # k3s API endpoint Cilium's kube-proxy replacement dials. This is the prod CONTROL-PLANE VIP
      # (kube-vip), NOT .20 (the ingress VIP) and NOT the single node address .10. It is owned
      # Ansible-side (prod inventory k3s_api_host) and MUST equal that value — [parity] contract in
      # platform/cilium/helmrelease.yaml. Not yet decided.
      - op: replace
        path: /data/K3S_API_HOST
        value: "192.168.2.10"
      # Pinned L4 VIPs, both carved out of the pool by lbipam.cilium.io/ips. Not yet assigned for
      # prod. Leaving the dev literals in place would hand a prod LoadBalancer a dev-LAN address, so
      # they stay placeholders; whatever is chosen MUST fall inside [POOL_START, POOL_STOP] and not
      # collide with the Gateway VIP or the node IPs (.10/.11/.12).
      - op: replace
        path: /data/UNIFI_L4_VIP
        value: "192.168.2.21"
      - op: replace
        path: /data/CRAFTY_L4_VIP
        value: "192.168.2.22"
      # Off-cluster DR target. Dev's versitygw/MinIO (192.168.1.9:9000) sits on the DEV side of the
      # network — a prod backup written there is not off-cluster DR and would mix two environments'
      # PITR streams in one bucket. Operator supplies the prod endpoint (full URL incl. scheme+port).
      - op: replace
        path: /data/S3_BACKUP_ENDPOINT
        value: "TBD-PROD-S3-BACKUP-ENDPOINT"
      # TODO(WS-INFRA, Phase 7): pin prod node placement once the bare-metal role labels exist.