longhorn: tolerate failover node

.gitignore

@@ -9,3 +9,6 @@ terraform.tfstate.backup
 kubeconfig
 talosconfig
 
+# Ignore rendered Talos machine configs (may contain cluster secrets)
+p330.yaml
+

infra/p330/kube/main.tf

@@ -0,0 +1,195 @@
+# Talos node for the P330 — joins the r740 "kube" cluster.
+terraform {
+  required_providers {
+    talos = {
+      source  = "siderolabs/talos"
+      version = "0.9.0"
+    }
+    null = {
+      source  = "hashicorp/null"
+      version = "3.2.3"
+    }
+  }
+}
+
+# Read the r740 kube module state to reuse the cluster secrets & endpoint.
+# The r740 module exposes: client_configuration, machine_secrets, cluster_name,
+# cluster_endpoint, kube_host.
+data "terraform_remote_state" "r740_kube" {
+  backend = var.r740_backend
+
+  config = var.r740_backend == "local" ? {
+    path = "${var.r740_state_path}/terraform.tfstate"
+  } : var.r740_backend_config
+}
+
+locals {
+  cluster_name     = data.terraform_remote_state.r740_kube.outputs.cluster_name
+  cluster_endpoint = data.terraform_remote_state.r740_kube.outputs.cluster_endpoint
+  machine_secrets  = data.terraform_remote_state.r740_kube.outputs.machine_secrets
+  client_config    = data.terraform_remote_state.r740_kube.outputs.client_configuration
+
+  # kubeconfig produced by the r740 kube module — used to wait for the node and
+  # apply labels/taints. There is no in-tree kubernetes provider here on
+  # purpose: managing a `kubernetes_node` resource conflicts with the node
+  # object that kubelet itself creates, so we use a null_resource with kubectl
+  # to wait + label + taint idempotently.
+  kubeconfig_path = "${var.r740_state_path}/kubeconfig"
+
+  # Network config: static if node_subnet is provided, otherwise Talos DHCPs.
+  static_network = var.node_subnet == null ? {} : {
+    interfaces = [{
+      interface = var.network_interface
+      addresses = [var.node_subnet]
+      routes    = var.node_gateway == null ? [] : [{ gateway = var.node_gateway }]
+    }]
+  }
+
+  network_patch = {
+    nameservers = var.nameservers
+  }
+  network_patch_merged = merge(local.network_patch, local.static_network)
+
+  machine_patch = {
+    install = {
+      image = var.installer_image
+      disk  = var.install_disk
+    }
+    network = merge(local.network_patch_merged, {
+      # Pin the Kubernetes node name. Talos otherwise auto-generates a hostname
+      # (e.g. "talos-8ec-vd1"), so the node registers with that random name
+      # instead of var.p330_node_name — and our label/taint null_resource waits
+      # for the wrong node. Setting machine.network.hostname fixes the node name.
+      hostname = var.p330_node_name
+    })
+    # Kernel modules required by Longhorn (iSCSI + ext4) — must match the
+    # control-plane nodes so Longhorn can schedule replicas on the failover node.
+    kernel = {
+      modules = [
+        { name = "iscsi_tcp" },
+        { name = "libiscsi" },
+        { name = "scsi_transport_iscsi" },
+        { name = "ext4" },
+      ]
+    }
+    sysctls = {
+      "fs.inotify.max_user_instances" = "1024"
+      "fs.inotify.max_user_watches"   = "1048576"
+    }
+    kubelet = {
+      # Keep the failover node from accumulating non-essential DaemonSet pods
+      # via the regular scheduler; the taint does the heavy lifting, this is
+      # belt-and-braces.
+      extraArgs = {
+        "register-with-taints" = "${var.failover_taint_key}=${var.failover_taint_value}:${var.failover_taint_effect}"
+      }
+    }
+  }
+}
+
+# Control-plane machine configuration. machine_type = "controlplane" makes
+# Talos generate a join config that runs the apiserver/controller-manager/
+# scheduler AND joins the existing etcd cluster as a new member (the cluster
+# was already bootstrapped by the r740 module's talos_machine_bootstrap).
+data "talos_machine_configuration" "p330" {
+  cluster_name     = local.cluster_name
+  machine_type     = "controlplane"
+  cluster_endpoint = local.cluster_endpoint
+  machine_secrets  = local.machine_secrets
+  config_patches = [
+    yamlencode({
+      machine = local.machine_patch
+    })
+  ]
+}
+
+# Rendered config is written to disk so it can also be applied manually with
+# `talosctl apply-config --nodes <p330_host> --file p330.yaml` if needed.
+resource "local_file" "p330_machine_config" {
+  filename = "${path.module}/p330.yaml"
+  content  = data.talos_machine_configuration.p330.machine_configuration
+}
+
+# Apply the machine config to the running (maintenance-mode) node over the
+# Talos API. Because the config patch contains a `machine.install` block, when
+# Talos receives this config on a node booted from the USB (maintenance) image
+# it installs itself to install.disk and reboots into the installed system.
+# For a controlplane node it then joins the existing etcd cluster as a new
+# member and runs the control-plane components; for a worker it just registers
+# via kubelet.
+resource "talos_machine_configuration_apply" "p330" {
+  client_configuration        = local.client_config
+  machine_configuration_input = data.talos_machine_configuration.p330.machine_configuration
+  node                        = var.p330_host
+  depends_on                  = [local_file.p330_machine_config]
+}
+
+# Emit a talosconfig scoped to this node for ad-hoc `talosctl` use.
+data "talos_client_configuration" "p330" {
+  cluster_name         = local.cluster_name
+  client_configuration = local.client_config
+  nodes                = [var.p330_host]
+}
+
+resource "local_file" "talosconfig" {
+  content    = data.talos_client_configuration.p330.talos_config
+  filename   = "${path.module}/talosconfig"
+  depends_on = [data.talos_client_configuration.p330]
+}
+
+# Wait for the node to register with Kubernetes (kubelet creates the Node
+# object after Talos installs and reboots), then label it and (re)apply the
+# failover taint. This is idempotent: kubectl exits 0 if the label/taint already
+# exists. The taint is also set via kubelet `register-with-taints`, so this
+# null_resource is a safety net for manual edits / drift.
+resource "null_resource" "p330_node_label_and_taint" {
+  triggers = {
+    node       = var.p330_node_name
+    key        = var.failover_taint_key
+    value      = var.failover_taint_value
+    effect     = var.failover_taint_effect
+    kubeconfig = local.kubeconfig_path
+  }
+
+  provisioner "local-exec" {
+    # Wait for the node to show up, then label + taint. The wait loop is bounded
+    # by kubectl --timeout; tune it via TF_LOG / re-run if the node is slow to
+    # join (a controlplane node must first complete the etcd join handshake).
+    command = <<-EOT
+      set -euo pipefail
+      KUBECONFIG="${local.kubeconfig_path}"
+      export KUBECONFIG
+      NODE="${var.p330_node_name}"
+
+      echo "Waiting for node $NODE to be registered (kubelet creates the Node object once Talos has installed, rebooted and joined etcd)..."
+      # kubectl wait --for=condition=Ready fails instantly with NotFound if the
+      # node object doesn't exist yet, so poll for existence first.
+      # /bin/sh (dash) has no $SECONDS, so count iterations with a bounded loop.
+      tries=240   # 240 * 5s = 20 minutes max
+      until kubectl get node "$NODE" >/dev/null 2>&1; do
+        tries=$((tries - 1))
+        if [ "$tries" -le 0 ]; then
+          echo "Timed out waiting for node $NODE to register." >&2
+          exit 1
+        fi
+        sleep 5
+      done
+      echo "Node $NODE registered. Waiting for it to become Ready..."
+
+      # Now wait for Ready (a controlplane node needs etcd joined + apiserver up).
+      kubectl wait --for=condition=Ready "node/$NODE" --timeout=20m || \
+        kubectl wait --for=jsonpath='{.status.conditions[?(@.reason=="KubeletReady")].status}'=True "node/$NODE" --timeout=20m
+
+      # Failover marker + taint (applied to both controlplane and worker nodes).
+      kubectl label --overwrite node "$NODE" homeprod.io/failover=true
+
+      # Apply the taint idempotently (kubectl taint --overwrite is a no-op if it exists).
+      kubectl taint --overwrite node "$NODE" \
+        "${var.failover_taint_key}=${var.failover_taint_value}:${var.failover_taint_effect}"
+
+      echo "Node $NODE ready, labeled and tainted for failover-only scheduling."
+    EOT
+  }
+
+  depends_on = [talos_machine_configuration_apply.p330]
+}

infra/p330/kube/variables.tf

@@ -0,0 +1,118 @@
+# Variables for the P330 Talos worker node that joins the r740 cluster.
+
+variable "p330_host" {
+  description = "Reachable IP/hostname of the P330 Talos node (for Talos API access)."
+  type        = string
+}
+
+variable "p330_node_name" {
+  description = "Kubernetes/Talos node name for the P330 (e.g. p330)."
+  type        = string
+  default     = "p330"
+}
+
+variable "r740_state_path" {
+  description = <<EOT
+Path to the Terraform state of the r740 kube module, used by terraform_remote_state
+to read the cluster secrets and endpoint so this node can join the existing cluster.
+Path is resolved by terraform_remote_state relative to the working directory where
+terraform runs (this module dir). The default points two levels up to the repo
+root and back down to the r740 kube module.
+EOT
+  type        = string
+  default     = "../../r740/kube"
+}
+
+variable "r740_backend" {
+  description = <<EOT
+Terraform backend type used by the r740 kube module.
+Set to "local" (default) when r740 uses a local tfstate file in its own directory,
+or the matching remote backend name ("s3", "remote", ...) if the r740 module uses
+a configured backend.
+EOT
+  type        = string
+  default     = "local"
+}
+
+variable "r740_backend_config" {
+  description = <<EOT
+Backend configuration map passed to terraform_remote_state when r740_backend is
+not "local". For a local backend this is ignored.
+EOT
+  type        = map(string)
+  default     = {}
+}
+
+variable "installer_image" {
+  description = <<EOT
+Talos installer image to use on the P330 (bare metal).
+Must be a **metal** Image Factory build that includes ixgbe.allow_unsupported_sfp=1
+in the kernel command line (sd-boot/UKI ignores machine.install.extraKernelArgs, so
+the param must be baked into the image). The default is a custom factory build
+(a18165114...).
+EOT
+  type        = string
+  default     = "factory.talos.dev/installer/a18165114f80c28601d05bc4ff1f6ea6d6b214882c5b9af7928aaf4d09741beb:v1.13.6"
+}
+
+variable "install_disk" {
+  description = "Block device path to install Talos on (e.g. /dev/sda, /dev/nvme0n1)."
+  type        = string
+  default     = "/dev/nvme0n1"
+}
+
+variable "node_subnet" {
+  description = <<EOT
+Static IPv4 address in CIDR notation for the P330 node (e.g. 10.1.2.132/24).
+Set to null to use DHCP. A static address is recommended for a failover node so
+DNS/affinity rules stay stable.
+EOT
+  type        = string
+  default     = "10.1.2.132/24"
+}
+
+variable "node_gateway" {
+  description = "IPv4 gateway for the P330 node. Ignored when node_subnet is null."
+  type        = string
+  default     = "10.1.2.1"
+}
+
+variable "network_interface" {
+  description = <<EOT
+Primary network interface name on the P330. Defaults to enp3s0f1 (the 10G Intel
+X520 NIC), which must be on the same L2/subnet as the r740 control plane so etcd
+peer traffic (TLS-verified against the r740's etcd cert SANs) doesn't cross a
+router. eno1 (1G) is left unconfigured.
+EOT
+  type        = string
+  default     = "enp3s0f1"
+}
+
+variable "nameservers" {
+  description = "DNS nameservers configured on the node (must work independently of kube)."
+  type        = list(string)
+  default     = ["10.1.2.148", "1.1.1.1"]
+}
+
+variable "failover_taint_key" {
+  description = "Taint key applied to the node to reserve it for failover workloads."
+  type        = string
+  default     = "dedicated"
+}
+
+variable "failover_taint_value" {
+  description = "Taint value applied to the node."
+  type        = string
+  default     = "failover"
+}
+
+variable "failover_taint_effect" {
+  description = "Taint effect applied to the node (NoSchedule / NoExecute)."
+  type        = string
+  default     = "NoSchedule"
+
+  validation {
+    condition     = contains(["NoSchedule", "PreferNoSchedule", "NoExecute"], var.failover_taint_effect)
+    error_message = "failover_taint_effect must be NoSchedule, PreferNoSchedule or NoExecute."
+  }
+}

infra/r740/kube/main.tf

@@ -40,7 +40,9 @@ data "talos_machine_configuration" "kube" {
     yamlencode({
       machine = {
         install = {
-          image = "factory.talos.dev/installer/ce4c980550dd2ab1b17bbf2b08801c7eb59418eafe8f279833297925d67c7515:v1.11.5"
+          # Image Factory image with iSCSI extension for Longhorn.
+          # Generated at https://factory.talos.dev — siderolabs/iscsi-tools + qemu-guest-agent
+          image = "factory.talos.dev/installer/dc7b152cb3ea99b821fcb7340ce7168313ce393d663740b791c36f6e95fc8586:v1.13.6"
         }
         network = {
           nameservers = [
@@ -53,6 +55,28 @@ data "talos_machine_configuration" "kube" {
         certSANs = [
           "${var.kube_host}", "${var.kube_hostname}"
         ]
+        # Kernel modules required by Longhorn (iSCSI + ext4)
+        kernel = {
+          modules = [
+            {
+              name = "iscsi_tcp"
+            },
+            {
+              name = "libiscsi"
+            },
+            {
+              name = "scsi_transport_iscsi"
+            },
+            {
+              name = "ext4"
+            },
+          ]
+        }
+        # Sysctls for Longhorn
+        sysctls = {
+          "fs.inotify.max_user_instances"  = "1024"
+          "fs.inotify.max_user_watches"    = "1048576"
+        }
       }
       cluster = {
         clusterName = "kube-${var.physical_hostname}"
@@ -106,6 +130,33 @@ output "kubeconfig" {
   value = talos_cluster_kubeconfig.kube.kubeconfig_raw
 }
 
+output "client_configuration" {
+  description = "Talos client configuration (sensitive) used to manage nodes."
+  sensitive   = true
+  value       = talos_machine_secrets.kube.client_configuration
+}
+
+output "machine_secrets" {
+  description = "Talos machine secrets (sensitive) used to generate node configs."
+  sensitive   = true
+  value       = talos_machine_secrets.kube.machine_secrets
+}
+
+output "cluster_name" {
+  description = "Name of the Talos cluster the worker joins."
+  value       = "kube-${var.physical_hostname}"
+}
+
+output "cluster_endpoint" {
+  description = "Endpoint (host:port) of the Talos/Kubernetes API on the cluster."
+  value       = "https://${var.kube_host}:6443"
+}
+
+output "kube_host" {
+  description = "Reachable IP/hostname of the control-plane node."
+  value       = var.kube_host
+}
+
 resource "local_file" "kubeconfig" {
     content     = "${talos_cluster_kubeconfig.kube.kubeconfig_raw}"
     filename = "${path.module}/kubeconfig"

kubernetes/system/coredns/zone-configmap.yaml

@@ -30,6 +30,9 @@ data:
     docker-r740     IN  A   10.1.2.212
     truenas         IN  A   10.1.2.139
 
+    ; P330
+    p330            IN  A   10.1.2.132
+
     ; PVE
     pve             IN  A   10.1.2.10
     docker-homeprod IN  A   10.1.2.12

kubernetes/system/longhorn/values.yaml

@@ -23,14 +23,31 @@ longhorn-ui:
     replicas: 1
 longhorn-manager:
     tolerations:
-        - key: ENC[AES256_GCM,data:HXcRGwnZkabc9hqnCNMYN05JYriiMQx7A7qTWXFvSvrHrBNP/A==,iv:obaOkaDCXPf1krWzs2XX3K2tKNQmDIAjCI7axto4q4o=,tag:2PQeZIy6E4UyEyDGjqqmpg==,type:str]
+        - key: ENC[AES256_GCM,data:yWX0dGIIpvCVOeZbvY7Jjbr/t8mcyLiLmzHrCz0bwXIBRgG0Ig==,iv:m1wOItluKgql41BzKoBvgyjBaG7Fplz1c4ScONjZ/c8=,tag:g+7730DA8KzK/7ApgumDcQ==,type:str]
           operator: Exists
           effect: NoSchedule
+        # Tolerate failover nodes so longhorn-manager runs there
+        - key: ENC[AES256_GCM,data:PksAIja6KV8+,iv:oDJ47xFoCKysl8yf9EQVJp9PGLKJQMWUOsIAcirjzJM=,tag:n9HVtUsERVmlQqeXpObvWQ==,type:str]
+          value: ENC[AES256_GCM,data:JDsyDMHMh0k=,iv:D3oVkD3tsxVE1hvcMcCYogoD7IVetrAbMzp6VCTOF6s=,tag:/cx/tQuGf1ImsVTZkwwt6A==,type:str]
+          operator: Equal
+          effect: NoSchedule
 longhorn-driver-deployer:
     tolerations:
-        - key: ENC[AES256_GCM,data:NOHqzVl7VyrhnoS7UzdYuFDRReXnfb7gZKyEHwJkYJtVUbaZaA==,iv:P9v9AV2mKt6uPiKUU/2RW8Ncpefn9fbz1bmcVgUg2zQ=,tag:Qfy2EpKVyKWGlK/OgkY4Hw==,type:str]
+        - key: ENC[AES256_GCM,data:lv255SLl898RJh8gx569wM+lL/YF8AUXhKuwEY5RUmw84z96Vg==,iv:3gY3OSeoVitIZd4rMgZK18bI9xtcsk1T0U0PphLZSZw=,tag:TMZLWxRTZB9fwNIThytnxw==,type:str]
           operator: Exists
           effect: NoSchedule
+        - key: ENC[AES256_GCM,data:dI3C6OPdnAW0,iv:G5vU4nypD3s/vffdQneasxHzUUXHsgUThjUtYKRfk7U=,tag:SD08w8Gz1WDaee/cM89hZA==,type:str]
+          value: ENC[AES256_GCM,data:GsbeabJMKjQ=,iv:qA+wC10BjpzMprPgoLeiBKAU1RcSef/yMfDzWbgAJ/s=,tag:9qS5tquOU7EkZ7hrd+VZhw==,type:str]
+          operator: Equal
+          effect: NoSchedule
+# instance-manager is a DaemonSet that places engine/replica pods on storage
+# nodes — it must tolerate the failover taint
+longhorn-instance-manager:
+    tolerations:
+        - key: ENC[AES256_GCM,data:3EHDHYKTaDyk,iv:D6z907ohAGqkoytBZ7s1aWJI6tRPsF7N798MwF9um+Q=,tag:zvEM2dzoWx4kLbIrbVW45Q==,type:str]
+          value: ENC[AES256_GCM,data:D9mG3tOtQas=,iv:JpbQDYKMZvNQSkoxw+1zwTeIrdrIr09oa7v8tZupSb0=,tag:5ypuOjneHKzSsJEXE4enxA==,type:str]
+          operator: Equal
+          effect: NoSchedule
 # Disable ingress for now
 ingress:
     enabled: false
@@ -55,27 +72,27 @@ recurringJobs:
           labels:
             type: backup
 sops:
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+    lastmodified: "2026-07-21T20:19:40Z"
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     pgp:
-        - created_at: "2026-07-18T14:22:17Z"
+        - created_at: "2026-07-21T20:19:40Z"
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+            55EedJBrvFbxWU9QP1dEUpcELGXroiOowjGM4cushYgeBZzXJkTMg7JmoB+HNiWY
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+            BxFEkapXY0Y89h6uFH7FKz0MiniojA4zvNFt2LQYICWXdUAJqqpeIRv88iUJkKDv
+            THVf7+wltQ4EHTuu4E0rCsg+3GeOIIYkBrLESjEsaSvQ/B+Iz9JgUFRkRr7lVvzS
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+            tKqNQBSsUmYlXIyize8d+ueVQcldN91bwpOXVmVIbghFX2Cp3H+4R5qfJxpH6yA=
+            =03zX
             -----END PGP MESSAGE-----
           fp: DC6910268E657FF70BA7EC289974494E76938DDC
     encrypted_regex: ^(password|value|ssh-key|api-key|user|username|privateKey|clientSecret|clientId|apiKey|extraArgs.*|.*Secret.*|extraEnvVars|.*SECRET.*|.*secret.*|key|.*Password|.*\.ya?ml)$