9 Commits

Author SHA1 Message Date
76ed2ffc14 fix(arm64): resolve dual-glibc loading that triggers stack-canary aborts
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Second nft crash report from QEMU virt:

  failed to set up pod masquerade
    nft add table ip kubesolo-masq:
      signal: aborted (output: *** stack smashing detected ***: terminated)

Root cause: two glibcs are visible to dynamically-linked binaries in the
rootfs. piCore64 ships glibc at /lib/libc.so.6; we copy the build host's
glibc (for the iptables-nft / nft / xtables-modules family) to
/lib/$LIB_ARCH/libc.so.6. The dynamic linker can resolve one binary's
NEEDED libc.so.6 to piCore's and another (via transitive load through
e.g. libnftables.so.1) to ours. Each libc has its own __stack_chk_guard
global; stack frames whose canary was written by code from libc-A and
checked by code from libc-B trip "stack smashing detected" → SIGABRT.
This didn't fire before nft was added because no host-installed dyn
binary actually got invoked before kubesolo crashed at first-boot
preflight.

Three layered fixes in inject-kubesolo.sh:

1. Bundle the full glibc family (was just libc.so.6 + ld). Now also
   libpthread, libdl, libm, libresolv, librt, libanl, libgcc_s. Without
   these, transitively-loaded host libs could pull them in from piCore's
   /lib and re-introduce the split.

2. After bundling, delete piCore's duplicates from /lib/ where our copy
   exists in /lib/$LIB_ARCH/. The dynamic linker's search now has
   exactly one match per soname.

3. Write /etc/ld.so.conf giving /lib/$LIB_ARCH precedence over /lib, and
   run `ldconfig -r "$ROOTFS"` to bake an explicit /etc/ld.so.cache.
   The runtime linker uses the cache (when present) instead of falling
   back to compiled-in default paths, making lookup order deterministic.

Also done (followups from previous commit):

- build/Dockerfile.builder gains nftables so docker-build picks up nft.
- .gitea/workflows/release.yaml's amd64 build job installs iptables +
  nftables (previously only listed iptables-related libs but not the
  CLIs themselves).

Verified by shellcheck. End-to-end QEMU verification on the Odroid next.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-15 07:56:49 -06:00
28de656b97 feat(update): OCI registry distribution for update artifacts
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Phase 7 of v0.3. The update agent can now pull update artifacts from any
OCI-compliant registry (ghcr.io, quay.io, harbor, zot, etc.) alongside the
existing HTTP latest.json protocol. Multi-arch artifacts are resolved
through manifest indexes so the same tag (e.g. "stable") yields the
right kernel + initramfs for runtime.GOARCH.

New package update/pkg/oci (~280 LOC, 9 tests):
- Client wraps oras-go/v2's remote.Repository. NewClient parses
  host/path references; WithPlainHTTP toggle for httptest.
- FetchMetadata resolves a tag and returns image.UpdateMetadata from
  manifest annotations (io.kubesolo.os.{version,channel,architecture,
  min_compatible_version,release_notes,release_date}). No blobs fetched.
- Pull resolves the tag, walks index → arch-specific manifest, downloads
  kernel + initramfs layers identified by their custom media types
  (application/vnd.kubesolo.os.kernel.v1+octet-stream and
  application/vnd.kubesolo.os.initramfs.v1+gzip), verifies their digests
  against the manifest, returns the same image.StagedImage shape the
  HTTP client produces.
- Cross-arch single-arch manifests are refused via the AnnotArch check
  (defense in depth on top of the gates in cmd/apply.go).
- Tests use a hand-rolled httptest registry implementing /v2/probe,
  manifest fetch by tag-or-digest, blob fetch by digest. Cover index
  arch-selection, single-arch manifests, missing-arch error, tampered
  blob rejection (digest mismatch), and reference parsing.

Dependencies added: oras.land/oras-go/v2 v2.6.0 plus its transitive
opencontainers/{go-digest,image-spec} and golang.org/x/sync. All small
and well-maintained; total binary size impact is negligible relative to
the existing 6.1 MB update agent.

cmd/apply.go:
- New --registry and --tag flags; mutually exclusive with --server.
- applyMetadataGates extracted as a helper, called from both transports
  so channel/arch/min-version policy is enforced identically regardless
  of how metadata was fetched.
- State transitions identical to the HTTP path: Checking → Downloading
  → Staged, with RecordError on any failure.

cmd/opts.go: --registry, --tag CLI flags. update.conf "server=" already
accepts either an HTTP URL or an OCI ref; the agent distinguishes by
which CLI/conf field carries the value.

build/scripts/push-oci-artifact.sh: new tool that publishes a single-arch
update artifact via the oras CLI with our custom media types and
annotations. After running for each arch, the operator composes the
multi-arch index with `oras manifest index create`. Documented inline.

build/Dockerfile.builder: installs oras 1.2.3 from upstream releases so
the Gitea Actions build container can run the new script.

Signature verification on the OCI path is intentionally deferred — the
artifact format is digest-verified end-to-end via oras-go, and Ed25519
signature consumption via OCI referrers is a follow-up. Plain HTTP
clients keep their existing signature path.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
2026-05-14 18:58:38 -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
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
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
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
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
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