Commit Graph

42 Commits

Author SHA1 Message Date
1b44c9d621 feat: bump KubeSolo to v1.1.5 + cross-arch CI workflow
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Phase 4 of v0.3 — KubeSolo version bump and CI gating.

KubeSolo v1.1.0 → v1.1.5 brings:
- New flag --disable-ipv6 (v1.1.5)
- New flag --db-wal-repair (v1.1.5) — important for power-loss resilience
  on edge appliances; surfaced as kubesolo.db-wal-repair in cloud-init
- New flag --full (v1.1.4) — disables edge-optimised k8s overrides
- Pod egress connectivity fix after reboot (v1.1.4)
- Registry config persistence fix (v1.1.5)
- k8s 1.34.7, CoreDNS 1.14.3, Go 1.26.2

All three new flags wired into cloud-init: config.go fields, kubesolo.go
extra-flag emission, full-config.yaml example.

Supply-chain hygiene:
- Per-arch checksums: KUBESOLO_SHA256_AMD64 and KUBESOLO_SHA256_ARM64 in
  versions.env. Replaces the single shared KUBESOLO_SHA256 that couldn't
  meaningfully verify both binaries at once.
- Checksum now applied to the tarball (the immutable upstream artifact)
  rather than the post-extract binary.

CI:
- New .gitea/workflows/build-arm64.yaml routes the full kernel + rootfs +
  disk-image build to the Odroid arm64-linux runner. Triggers on push to
  main, tags, and manual workflow_dispatch. The boot smoke test is
  continue-on-error because KubeSolo's first-boot image import deadline
  fires under QEMU TCG on the Odroid.

VERSION bumped to 0.3.0-dev. CHANGELOG entry under [0.3.0-dev] captures all
Phase 1-4 work + the known limitations documented in arm64-status.md.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 16:26:20 -06:00
de10de0ef3 chore(arm64): clean up debug logging + document Phase 3 status
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Remove [KSOLO-DBG] per-step echos from init.sh. The /dev/console redirect
stays — it's load-bearing for early-boot visibility on QEMU virt.

Add docs/arm64-status.md capturing the end-of-Phase-3 state:
  - What works (full boot through 14 stages, KubeSolo + containerd start)
  - Known limitations of the dev setup (QEMU TCG perf, /dev/vda4 hardcode,
    busybox-static gaps)
  - What's needed to ship v0.3 ARM64 as production-ready

Real-hardware validation (Graviton, Ampere, or similar) is the next gating
step before we can call ARM64 generic done.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 16:19:16 -06:00
1de36289a5 fix(arm64): tr -d '[:space:]' is parsed as literal char-set by busybox 1.30.1
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Ubuntu's busybox-static 1.30.1 (which we use for the ARM64 rootfs after
piCore64's BusyBox crashes in QEMU virt) doesn't recognize POSIX character
classes. `tr -d '[:space:]'` is interpreted as "delete any of the literal
characters [, :, s, p, a, c, e, ]" — so every s/p/a/c/e in module names and
sysctl keys gets eaten.

Symptoms in the boot log:
  virtio_net  -> virtio_nt   (e dropped)
  overlay     -> ovrly       (e, a dropped)
  bridge      -> bridg       (e dropped)
  nf_conntrack -> nf_onntrk  (c, a, c dropped)
  net.bridge.bridge-nf-call-iptables -> nt.bridg.bridg-nf-ll-itbl

Fix: use explicit whitespace chars `tr -d ' \t\r\n'` in both
30-kernel-modules.sh and 40-sysctl.sh. Works under any tr implementation.

Also: filter functions.sh out of the init.d stage-copy loop. It's a shared
library (sourced by init.sh), not a numbered stage. With it in init.d the
main loop runs it as a stage after stage 90, then panics with "Init
completed without exec'ing KubeSolo".

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 16:02:21 -06:00
31aac701db debug(arm64): use /dev/vda4 directly instead of LABEL=KSOLODATA
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piCore64's blkid/findfs binaries (separate util-linux dynamics, NOT busybox
symlinks) crash in QEMU virt with the same instruction-abort issue as the
broken BusyBox. The host's static busybox doesn't include blkid/findfs
applets either, so stage 20-persistent-mount.sh segfaults in a loop trying
to resolve LABEL=KSOLODATA.

Short-term: hardcode /dev/vda4 (the virtio data partition under QEMU) so
the boot can progress past stage 20 and we can see what else needs fixing.

Pre-v0.3 release we need to either:
  a) ship a real blkid/findfs binary that works (util-linux from upstream,
     statically built), or
  b) avoid LABEL= entirely and detect the data partition by walking
     /sys/class/block looking for our ext4 magic+label.

Either way the LABEL= path needs to work on real ARM64 hosts where the
device path varies (vda/sda/nvme0n1).

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 15:47:55 -06:00
06e12a79bd fix(arm64): override piCore64's BusyBox with host's static busybox
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piCore64 v15.0.0 ships BusyBox built with ARM instructions that QEMU virt
cannot emulate even under -cpu max — applets like mkdir, uname, readlink
SIGILL on first invocation (el0_undef in the panic trace). mount works
because piCore's busybox.suid happens to use a different code path.

Fix: when building the arm64 rootfs, replace piCore's bin/busybox and
bin/busybox.suid with /bin/busybox from the build host (Ubuntu's
busybox-static, statically linked, built for generic ARMv8-A).

Also add busybox-static to Dockerfile.builder so the Docker-based build
flow has the same fallback available.

Long-term: source a known-good ARM64 BusyBox build (Alpine, or our own
from upstream BusyBox) so we don't depend on the build host's package
manager. Tracked as future work.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 15:38:05 -06:00
dc48caa959 debug: log every step of pre-switch_root mount sequence to /dev/console
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The ARM64 generic boot is failing with 'Segmentation fault' from a child
process before any visible init output. Adding per-step debug lines to
narrow down which mount/mkdir crashes.

To revert: git revert <this commit> before tagging v0.3.0.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 15:27:50 -06:00
65938d6d04 fix(qemu): use -cpu max so piCore64 binaries don't hit instruction aborts
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piCore64's BusyBox segfaults under QEMU virt with -cpu cortex-a72, generating
an EL0 Instruction Abort (el0_ia in the panic call trace). The binary is built
with ARMv8 extensions (likely +lse atomics, +crypto, or +fp16) that the
cortex-a72 model doesn't enable by default.

Switch to -cpu max which enables all emulated ARMv8 features. This is fine for
dev testing; the actual production hosts (Graviton, Ampere, real ARM64
hardware) all have these features natively.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 15:15:45 -06:00
5cf81049f6 fix: install our staged init at /init too, not just /sbin/init
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The kernel ALWAYS runs /init when booting from an initramfs. If /init doesn't
exist, the kernel falls back to the legacy root-mount path (looking for a real
root partition via root= cmdline), which we don't want — our system IS the
initramfs.

Previous fix removed piCore's /init to stop it from being run; that caused the
kernel to skip the initramfs entrypoint entirely and panic with 'Cannot open
root device' (error -6).

Correct fix: replace piCore's /init with a copy of our init.sh. The kernel
runs /init -> our staged boot, which is exactly what we want. Keep
/sbin/init as well (some boot paths exec it directly, e.g. via init= cmdline
override) and the existing init=/sbin/init in grub-arm64.cfg as a belt.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 15:01:20 -06:00
863f498cc2 fix: kernel must use /sbin/init, not piCore's /init
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Root cause of the 'Run /init as init process' -> immediate SIGSEGV panic on
the generic ARM64 boot: piCore64's rootfs ships a /init script at the rootfs
root, and the kernel's init search order picks /init over /sbin/init. piCore's
init then exec's something incompatible with our environment and segfaults.

Two fixes:
1. inject-kubesolo.sh now removes the upstream /init after replacing
   /sbin/init. This is the structural fix — the rootfs no longer has the
   conflicting entry-point.
2. grub-arm64.cfg passes init=/sbin/init explicitly. Belt-and-suspenders in
   case any future rootfs source re-introduces /init.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 14:43:35 -06:00
05ab108de1 fix(grub): put ttyAMA0 last so it's the primary console on ARM64
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Kernel takes the last `console=` argument as primary (where init's stdout/stderr
land). The previous order had ttyS0 last, which is a dead device on QEMU virt
and most ARM64 SBCs — so init output disappeared and we only saw kernel panic
messages (which use earlycon, bypassing the console preference).

Also drop `quiet` from the default boot entry while we stabilise — we need the
kernel + init output visible right now.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 14:11:58 -06:00
c20f5a2e8c fix(build): detect native ARM64 host and skip cross-compiler requirement
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build-kernel-arm64.sh and build-kernel-rpi.sh both insisted on
aarch64-linux-gnu-gcc (the cross-compiler from x86), which fails on a native
ARM64 build host like the Odroid runner. Detect uname -m and use the host's
gcc with an empty CROSS_COMPILE on aarch64 hosts.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 10:56:39 -06:00
80aca5e372 feat: ARM64 generic UEFI disk image (GPT + GRUB A/B)
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Produces a UEFI-bootable raw disk image for generic ARM64 hosts (QEMU virt,
Ampere/Graviton cloud, ARM64 SBCs with UEFI). Reuses the existing 4-partition
A/B layout from x86 (EFI 256 MB FAT32 + System A 512 MB ext4 + System B 512 MB
ext4 + Data ext4 remainder).

Changes:
- build/scripts/create-disk-image.sh: TARGET_ARCH env var (amd64 default,
  arm64). Selects kernel source path, grub-mkimage target (x86_64-efi vs
  arm64-efi), EFI binary name (bootx64.efi vs BOOTAA64.EFI), grub.cfg variant,
  and whether to also install BIOS GRUB (x86 only).
- build/grub/grub-arm64.cfg: ARM64 variant of grub.cfg. Identical A/B logic;
  console=ttyAMA0+ttyS0 to cover QEMU virt PL011, Ampere PL011, and Graviton
  16550-compat.
- build/Dockerfile.builder: add grub-efi-amd64-bin, grub-efi-arm64-bin,
  grub-pc-bin, grub-common, grub2-common so the builder container can produce
  EFI images for both architectures.
- hack/dev-vm-arm64.sh: split into kernel mode (direct -kernel/-initrd, fast
  iteration) and --disk mode (UEFI firmware + GRUB + disk image, full
  integration test). Probes common UEFI firmware paths on Ubuntu/Fedora/macOS.
  Default kernel path now points at kernel-arm64-generic/Image with fallback
  to the renamed custom-kernel-rpi/Image.
- test/qemu/test-boot-arm64-disk.sh: new CI test for the full UEFI -> GRUB ->
  kernel -> stage-90 boot chain. Uses a scratch copy of the disk so grubenv
  writes don't mutate the source artifact.
- Makefile: new disk-image-arm64 target (depends on rootfs-arm64 + kernel-arm64),
  new test-boot-arm64-disk target, .PHONY + help updates.

Phase 3 scaffold is in place. First real end-to-end ARM64 build runs in the
next step on the Odroid runner — that's where we find out what's actually
broken.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 10:36:08 -06:00
d51618badb build: separate generic ARM64 from Raspberry Pi kernel builds
Splits the ARM64 build into two tracks per docs/arm64-architecture.md:

Generic ARM64 (mainline kernel.org, UEFI, virtio, GRUB):
- New build/scripts/build-kernel-arm64.sh builds mainline LTS (6.12.x by default)
  from arm64 defconfig + shared container fragment + arm64-virt enables
  (VIRTIO_*, EFI_STUB, NVMe). Output: build/cache/kernel-arm64-generic/.
- New Makefile targets: kernel-arm64, rootfs-arm64 (now consumes the mainline
  kernel modules via TARGET_VARIANT=generic).
- versions.env: pin MAINLINE_KERNEL_VERSION=6.12.10, declare cdn.kernel.org URL
  and SHA256 placeholder.

Raspberry Pi (raspberrypi/linux fork, custom DTBs, autoboot.txt):
- build-kernel-arm64.sh (RPi-flavoured) renamed to build-kernel-rpi.sh; cache
  dir renamed from custom-kernel-arm64 to custom-kernel-rpi.
- New Makefile targets: kernel-rpi, rootfs-arm64-rpi (uses TARGET_VARIANT=rpi).
- rpi-image now depends on rootfs-arm64-rpi + kernel-rpi instead of the generic
  rootfs-arm64.
- create-rpi-image.sh + inject-kubesolo.sh updated to reference the new cache
  path. inject-kubesolo.sh now takes a TARGET_VARIANT env var (rpi|generic) to
  select which ARM64 kernel modules to consume.

Shared substrate:
- rpi-kernel-config.fragment renamed to kernel-container.fragment. The contents
  were never RPi-specific (cgroup, namespaces, AppArmor, netfilter) — just
  misnamed. Extended with extra subsystem disables (KVM, WLAN, CFG80211,
  INFINIBAND, PCMCIA, HAMRADIO, ISDN, ATM, INPUT_JOYSTICK, INPUT_TABLET, FPGA)
  and CONFIG_LSM=lockdown,yama,apparmor.
- build-kernel.sh (x86) refactored to apply the shared fragment via a generic
  apply_fragment function (two-pass for the TC stock config security dance),
  killing ~50 lines of inline config duplication.

Note: rename detection shows build-kernel-arm64.sh as 'modified' because the
new file at that path is the mainline build, while the old RPi-flavoured
content lives in build-kernel-rpi.sh (which appears as a new file). The git
log for build-kernel-rpi.sh is empty; the RPi history is preserved at the
original path until this commit.

No actual kernel build runs in this commit — that's Phase 3 work.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 10:30:11 -06:00
19b99cf101 docs: define generic ARM64 vs RPi build-track architecture
Phase 1 audit finding: existing ARM64 build code is mostly already generic.
Only build-kernel-arm64.sh and rpi-kernel-config.fragment are misnamed (the
former is RPi-only, the latter is actually arch-agnostic). The QEMU virt
harness, modules-arm64.list, extract-core arm64 branch, and inject-kubesolo
arm64 branch are all generic.

This document records the target two-track layout for v0.3.0:
- Generic ARM64: mainline kernel, UEFI, GRUB, virtio, GPT 4-part image
- Raspberry Pi: raspberrypi/linux fork, autoboot.txt, MBR 4-part image
- Shared: init, cloud-init, update agent, modules list, kernel-container fragment

Phases 2 and 3 will execute the migration (rename build-kernel-arm64.sh ->
build-kernel-rpi.sh, write a new mainline build-kernel-arm64.sh, etc.).

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 10:02:29 -06:00
059ec7955f chore: housekeeping for v0.3 prep
- Pin KUBESOLO_VERSION in versions.env (was soft-defaulted in fetch-components.sh)
- Gitignore screenshots, macOS resource forks, and common image extensions
- Update README roadmap: x86_64 stable, ARM64 generic in progress (v0.3),
  ARM64 RPi paused pending hardware
- Add docs/ci-runners.md documenting the Odroid arm64-linux Gitea runner

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 09:44:01 -06:00
a6c5d56ade rpi: drop to interactive shell on boot failure, add initcall_debug
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Instead of returning 1 (which triggers kernel panic via set -e before
emergency_shell runs), exec an interactive shell on /dev/console so
the user can run dmesg and debug interactively. Add initcall_debug
and loglevel=7 to cmdline.txt to show every driver probe during boot.
Also dump last 60 lines of dmesg before dropping to shell.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 20:50:20 -06:00
6c6940afac rpi: add boot diagnostics and remove quiet for debugging
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Remove 'quiet' from RPi cmdline.txt so kernel probe messages are
visible on HDMI. Add comprehensive diagnostics to the data device
error path: dmesg for MMC/SDHCI/regulators/firmware, /sys/class/block
listing, and error message scanning. This will reveal why zero block
devices appear despite all kernel configs being correct.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 20:12:26 -06:00
4e3f1d6cf0 fix: use kernel-built DTBs for RPi SD card driver probe
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The sdhci-iproc driver (RPi 4 SD card controller) probes via Device
Tree matching. Using DTBs from the firmware repo instead of the
kernel build caused a mismatch — the driver silently failed to probe,
resulting in zero block devices after boot.

Changes:
- Use DTBs from custom-kernel-arm64/dtbs/ (matches the kernel)
- Firmware blobs (start4.elf, fixup4.dat) still from firmware repo
- Also includes prior fix for LABEL= resolution in persistent mount

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
v0.2.0
2026-02-12 19:27:54 -06:00
6ff77c4482 fix: resolve LABEL= syntax for RPi data partition
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The cmdline uses kubesolo.data=LABEL=KSOLODATA, but the wait loop
in 20-persistent-mount.sh checked [ -b "LABEL=KSOLODATA" ] which
is always false — it's a label reference, not a block device path.

Fix by detecting LABEL= prefix and resolving it to a block device
path via blkid -L in the wait loop. Also loads mmc_block module as
fallback for platforms where it's not built-in.

Adds debug output listing available block devices on failure.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 19:05:10 -06:00
a2764218fc fix: make RPi partition 1 self-sufficient boot fallback
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The autoboot.txt A/B redirect requires newer RPi EEPROM firmware.
On older EEPROMs, autoboot.txt is silently ignored and the firmware
tries to boot from partition 1 directly — failing with a rainbow
screen because partition 1 had no kernel or initramfs.

Changes:
- Increase partition 1 from 32 MB to 384 MB
- Populate partition 1 with full boot files (kernel, initramfs,
  config.txt with kernel= directive, DTBs, overlays)
- Keep autoboot.txt for A/B redirect on supported EEPROMs
- When autoboot.txt works: boots from partition 2 (A/B scheme)
- When autoboot.txt is unsupported: boots from partition 1 (fallback)

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 18:52:21 -06:00
2ba816bf6e fix: add config.txt and DTBs to RPi boot control partition
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The Raspberry Pi firmware reads config.txt from partition 1 BEFORE
processing autoboot.txt. Without arm_64bit=1 on the boot control
partition, the firmware defaults to 32-bit mode and shows only a
rainbow square. Add minimal config.txt, device tree blobs, and
overlays to partition 1 so the firmware can initialize correctly
before redirecting to the A/B boot partitions.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 18:29:28 -06:00
65dcddb47e fix: RPi image uses MBR and firmware on boot partition
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- Switch from GPT to MBR (dos) partition table — GPT + autoboot.txt
  fails on many Pi 4 EEPROM versions
- Copy firmware blobs (start*.elf, fixup*.dat) to partition 1 (KSOLOCTL)
  so the EEPROM can find and load them
- Increase boot control partition from 16 MB to 32 MB to fit firmware
- Mark partition 1 as bootable

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 18:16:34 -06:00
ba4812f637 fix: complete ARM64 RPi build pipeline
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- fetch-components.sh: download ARM64 KubeSolo binary (kubesolo-arm64)
- inject-kubesolo.sh: use arch-specific binaries for KubeSolo, cloud-init,
  and update agent; detect KVER from custom kernel when rootfs has none;
  cross-arch module resolution via find fallback when modprobe fails
- create-rpi-image.sh: kpartx support for Docker container builds
- Makefile: rootfs-arm64 depends on build-cross, includes pack-initramfs

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 17:20:04 -06:00
09dcea84ef fix: disk image build, piCore64 URL, license
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- Add kpartx for reliable loop partition mapping in Docker containers
- Fix piCore64 download URL (changed from .img.gz to .zip format)
- Fix piCore64 boot partition mount (initramfs on p1, not p2)
- Fix tar --wildcards for RPi firmware extraction
- Add MIT license (same as KubeSolo)
- Add kpartx and unzip to Docker builder image

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 17:05:03 -06:00
a4e719ba0e chore: bump version to 0.2.0
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Includes cloud-init full flag support, security hardening, AppArmor,
and ARM64 Raspberry Pi support.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 16:36:05 -06:00
61bd28c692 feat: cloud-init supports all documented KubeSolo CLI flags
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Add missing flags (--local-storage-shared-path, --debug, --pprof-server,
--portainer-edge-id, --portainer-edge-key, --portainer-edge-async) so all
10 documented KubeSolo parameters can be configured via cloud-init YAML.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 15:49:31 -06:00
4fc078f7a3 fix: kubeconfig server accessible via port forwarding, integration tests use proper auth
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Bind kubeconfig HTTP server to 0.0.0.0:8080 (was 127.0.0.1) so integration
tests can reach it via QEMU SLIRP port forwarding. Add shared wait_for_boot
and fetch_kubeconfig helpers to qemu-helpers.sh. Update all 5 integration
tests to fetch kubeconfig via HTTP and use it for kubectl authentication.

All 6 tests pass on Linux with KVM: boot (18s), security (7/7), K8s ready
(15s), workload deploy, local storage, network policy.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 15:25:32 -06:00
6c15ba7776 fix: kernel AppArmor 2-pass olddefconfig and QEMU test direct kernel boot
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The stock TinyCore kernel config has "# CONFIG_SECURITY is not set" which
caused make olddefconfig to silently revert all security configs in a single
pass. Fix by applying security configs (AppArmor, Audit, LSM) after the
first olddefconfig resolves base dependencies, then running a second pass.
Added mandatory verification that exits on missing critical configs.

All QEMU test scripts converted from broken -cdrom + -append pattern to
direct kernel boot (-kernel + -initrd) via shared test/lib/qemu-helpers.sh
helper library. The -append flag only works with -kernel, not -cdrom.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 14:11:38 -06:00
958524e6d8 fix: Go version, test scripts, and shellcheck warnings from validation
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- Dockerfile.builder: Go 1.24.0 → 1.25.5 (go.mod requires it)
- test-boot.sh: use direct kernel boot via ISO extraction instead of
  broken -cdrom + -append; fix boot marker to "KubeSolo is running"
  (Stage 90 blocks on wait, never emits "complete")
- test-security-hardening.sh: same direct kernel boot and marker fixes
- run-vm.sh, dev-vm.sh, dev-vm-arm64.sh: quote QEMU -net args to
  silence shellcheck SC2054
- fetch-components.sh, fetch-rpi-firmware.sh, dev-vm-arm64.sh: fix
  trap quoting (SC2064)

Validated: full Docker build, 94 Go tests pass, QEMU boot (73s),
security hardening test (6/6 pass, 1 AppArmor skip pending kernel
rebuild).

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 13:30:55 -06:00
efc7f80b65 feat: add security hardening, AppArmor, and ARM64 Raspberry Pi support (Phase 6)
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Security hardening: bind kubeconfig server to localhost, mount hardening
(noexec/nosuid/nodev on tmpfs), sysctl network hardening, kernel module
loading lock after boot, SHA256 checksum verification for downloads,
kernel AppArmor + Audit support, complain-mode AppArmor profiles for
containerd and kubelet, and security integration test.

ARM64 Raspberry Pi support: piCore64 base extraction, RPi kernel build
from raspberrypi/linux fork, RPi firmware fetch, SD card image with 4-
partition GPT and tryboot A/B mechanism, BootEnv Go interface abstracting
GRUB vs RPi boot environments, architecture-aware build scripts, QEMU
aarch64 dev VM and boot test.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 13:08:17 -06:00
7abf0e0c04 build: add TINYCORE-MODIFICATIONS.md to .gitignore
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Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 11:38:01 -06:00
60d0edaf84 docs: update README with kubeconfig retrieval and Portainer Edge usage
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Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 10:50:44 -06:00
f3d86e4d8f fix: make dev-vm.sh work on Linux with fallback ISO extraction methods
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- Try bsdtar first (macOS + Linux with libarchive-tools)
- Fall back to isoinfo (genisoimage/cdrtools)
- Fall back to loop mount (Linux only, requires root)
- Platform-aware error messages for e2fsprogs install

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
v0.1.0
2026-02-12 02:21:58 -06:00
04a5179533 docs: update CHANGELOG with macOS dev VM fixes and Portainer Edge integration
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Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 02:13:01 -06:00
d9ac58418d fix: macOS dev VM, CA certs, DNS fallback, Portainer Edge integration
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- dev-vm.sh: rewrite for macOS (bsdtar ISO extraction, Homebrew mkfs.ext4
  detection, direct kernel boot, TCG acceleration, port 8080 forwarding)
- inject-kubesolo.sh: add CA certificates bundle from builder so containerd
  can verify TLS when pulling from registries (Docker Hub, etc.)
- 50-network.sh: add DNS fallback (10.0.2.3 + 8.8.8.8) when DHCP client
  doesn't populate /etc/resolv.conf
- 90-kubesolo.sh: serve kubeconfig via HTTP on port 8080 for reliable
  retrieval from host, add 127.0.0.1 and 10.0.2.15 to API server SANs
- portainer.go: add headless Service to Edge Agent manifest (required for
  agent peer discovery DNS lookup)
- 10-parse-cmdline.sh + init.sh: add kubesolo.edge_id/edge_key boot params
- 20-persistent-mount.sh: auto-format unformatted data disks on first boot
- hack/fix-portainer-service.sh: helper to patch running cluster

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-12 02:11:31 -06:00
36311ed4f4 docs: update README for all phases complete, add CHANGELOG
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README.md rewritten to reflect all 5 design-doc phases complete with
sections for custom kernel, cloud-init, atomic updates, monitoring,
full make targets table, and documentation links.

CHANGELOG.md created with detailed v0.1.0 release notes covering
all features across all phases.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-11 23:40:06 -06:00
39732488ef feat: custom kernel build + boot fixes for working container runtime
Build a custom Tiny Core 17.0 kernel (6.18.2) with missing configs
that the stock kernel lacks for container workloads:
- CONFIG_CGROUP_BPF=y (cgroup v2 device control via BPF)
- CONFIG_DEVTMPFS=y (auto-create /dev device nodes)
- CONFIG_DEVTMPFS_MOUNT=y (auto-mount devtmpfs)
- CONFIG_MEMCG=y (memory cgroup controller for memory.max)
- CONFIG_CFS_BANDWIDTH=y (CPU bandwidth throttling for cpu.max)

Also strips unnecessary subsystems (sound, GPU, wireless, Bluetooth,
KVM, etc.) for minimal footprint on a headless K8s edge appliance.

Init system fixes for successful boot-to-running-pods:
- Add switch_root in init.sh to escape initramfs (runc pivot_root)
- Add mountpoint guards in 00-early-mount.sh (skip if already mounted)
- Create essential device nodes after switch_root (kmsg, console, etc.)
- Enable cgroup v2 controller delegation with init process isolation
- Mount BPF filesystem for cgroup v2 device control
- Add mknod fallback from sysfs in 20-persistent-mount.sh for /dev/vda
- Move KubeSolo binary to /usr/bin (avoid /usr/local bind mount hiding)
- Generate /etc/machine-id in 60-hostname.sh (kubelet requires it)
- Pre-initialize iptables tables before kube-proxy starts
- Add nft_reject, nft_fib, xt_nfacct to kernel modules list

Build system changes:
- New build-kernel.sh script for custom kernel compilation
- Dockerfile.builder adds kernel build deps (flex, bison, libelf, etc.)
- Selective kernel module install (only modules.list + transitive deps)
- Install iptables-nft (xtables-nft-multi) + shared libs in rootfs

Tested: ISO boots in QEMU, node reaches Ready in ~35s, CoreDNS and
local-path-provisioner pods start and run successfully.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-11 23:13:31 -06:00
456aa8eb5b feat: add distribution and fleet management — CI/CD, OCI, metrics, ARM64 (Phase 5)
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- Gitea Actions CI pipeline: Go tests, build, shellcheck on push/PR
- Gitea Actions release pipeline: full build + artifact upload on version tags
- OCI container image builder for registry-based OS distribution
- Zero-dependency Prometheus metrics endpoint (kubesolo_os_info, boot,
  memory, update status) with 10 tests
- USB provisioning tool for air-gapped deployments with cloud-init injection
- ARM64 cross-compilation support (TARGET_ARCH env var + build-cross.sh)
- Updated build scripts to accept TARGET_ARCH for both amd64 and arm64
- New Makefile targets: oci-image, build-cross

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-11 11:36:53 -06:00
49a37e30e8 feat: add production hardening — Ed25519 signing, Portainer Edge, SSH extension (Phase 4)
Image signing:
- Ed25519 sign/verify package (pure Go stdlib, zero deps)
- genkey and sign CLI subcommands for build system
- Optional --pubkey flag for verifying updates on apply
- Signature URLs in update metadata (latest.json)

Portainer Edge Agent:
- cloud-init portainer.go module writes K8s manifest
- Auto-deploys Edge Agent when portainer.edge-agent.enabled
- Full RBAC (ServiceAccount, ClusterRoleBinding, Deployment)
- 5 Portainer tests in portainer_test.go

Production tooling:
- SSH debug extension builder (hack/build-ssh-extension.sh)
- Boot performance benchmark (test/benchmark/bench-boot.sh)
- Resource usage benchmark (test/benchmark/bench-resources.sh)
- Deployment guide (docs/deployment-guide.md)

Test results: 50 update agent tests + 22 cloud-init tests passing.

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-11 11:26:23 -06:00
8d25e1890e feat: add A/B partition updates with GRUB and Go update agent (Phase 3)
Implement atomic OS updates via A/B partition scheme with automatic
rollback. GRUB bootloader manages slot selection with a 3-attempt
boot counter that auto-rolls back on repeated health check failures.

GRUB boot config:
- A/B slot selection with boot_counter/boot_success env vars
- Automatic rollback when counter reaches 0 (3 failed boots)
- Debug, emergency shell, and manual slot-switch menu entries

Disk image (refactored):
- 4-partition GPT layout: EFI + System A + System B + Data
- GRUB EFI/BIOS installation with graceful fallbacks
- Both system partitions populated during image creation

Update agent (Go, zero external deps):
- pkg/grubenv: read/write GRUB env vars (grub-editenv + manual fallback)
- pkg/partition: find/mount/write system partitions by label
- pkg/image: HTTP download with SHA256 verification
- pkg/health: post-boot checks (containerd, API server, node Ready)
- 6 CLI commands: check, apply, activate, rollback, healthcheck, status
- 37 unit tests across all 4 packages

Deployment:
- K8s CronJob for automatic update checks (every 6 hours)
- ConfigMap for update server URL
- Health check Job for post-boot verification

Build pipeline:
- build-update-agent.sh compiles static Linux binary (~5.9 MB)
- inject-kubesolo.sh includes update agent in initramfs
- Makefile: build-update-agent, test-update-agent, test-update targets

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-11 11:12:46 -06:00
d900fa920e feat: add cloud-init Go parser (Phase 2)
Implement a lightweight cloud-init system for first-boot configuration:
- Go parser for YAML config (hostname, network, KubeSolo settings)
- Static/DHCP network modes with DNS override
- KubeSolo extra flags and API server SAN configuration
- Portainer Edge Agent and air-gapped deployment support
- New init stage 45-cloud-init.sh runs before network/hostname stages
- Stages 50/60 skip gracefully when cloud-init has already applied
- Build script compiles static Linux/amd64 binary (~2.7 MB)
- 17 unit tests covering parsing, validation, and example files
- Full documentation at docs/cloud-init.md

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-11 10:39:05 -06:00
e372df578b feat: initial Phase 1 PoC scaffolding for KubeSolo OS
Complete Phase 1 implementation of KubeSolo OS — an immutable, bootable
Linux distribution built on Tiny Core Linux for running KubeSolo
single-node Kubernetes.

Build system:
- Makefile with fetch, rootfs, initramfs, iso, disk-image targets
- Dockerfile.builder for reproducible builds
- Scripts to download Tiny Core, extract rootfs, inject KubeSolo,
  pack initramfs, and create bootable ISO/disk images

Init system (10 POSIX sh stages):
- Early mount (proc/sys/dev/cgroup2), cmdline parsing, persistent
  mount with bind-mounts, kernel module loading, sysctl, DHCP
  networking, hostname, clock sync, containerd prep, KubeSolo exec

Shared libraries:
- functions.sh (device wait, IP lookup, config helpers)
- network.sh (static IP, config persistence, interface detection)
- health.sh (containerd, API server, node readiness checks)
- Emergency shell for boot failure debugging

Testing:
- QEMU boot test with serial log marker detection
- K8s readiness test with kubectl verification
- Persistence test (reboot + verify state survives)
- Workload deployment test (nginx pod)
- Local storage test (PVC + local-path provisioner)
- Network policy test
- Reusable run-vm.sh launcher

Developer tools:
- dev-vm.sh (interactive QEMU with port forwarding)
- rebuild-initramfs.sh (fast iteration)
- inject-ssh.sh (dropbear SSH for debugging)
- extract-kernel-config.sh + kernel-audit.sh

Documentation:
- Full design document with architecture research
- Boot flow documentation covering all 10 init stages
- Cloud-init examples (DHCP, static IP, Portainer Edge, air-gapped)

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
2026-02-11 10:18:42 -06:00