feat: preflight storage needed to perform airgap install #2336

banjoh · 2025-06-18T12:19:06Z

What this PR does / why we need it:

Add host preflight checks to ensure nodes have enough storage to perform an airgap install when installing a new node, and when joining a node to an existing cluster. Separate preflights have been added for workers and controller type nodes.

Pending tasks

Running manual tests with a real airgap install to justify airgap multiplier. Its 2x at the moment, but might increase to 3x
Manual tests with new build to test the new preflights

Which issue(s) this PR fixes:

sc-123579

Does this PR require a test?

Automated tests to new changes added
Manual tests to check if preflight works

Does this PR require a release note?

Add host preflight to check storage needed to perform airgap install

Does this PR require documentation?

NONE

Signed-off-by: Evans Mungai <[email protected]>

github-actions · 2025-06-18T12:38:31Z

This PR has been released (on staging) and is available for download with a embedded-cluster-smoke-test-staging-app license ID.

Online Installer:

curl "https://staging.replicated.app/embedded/embedded-cluster-smoke-test-staging-app/ci/appver-dev-9f3562b" -H "Authorization: $EC_SMOKE_TEST_LICENSE_ID" -o embedded-cluster-smoke-test-staging-app-ci.tgz

Airgap Installer (may take a few minutes before the airgap bundle is built):

curl "https://staging.replicated.app/embedded/embedded-cluster-smoke-test-staging-app/ci-airgap/appver-dev-9f3562b?airgap=true" -H "Authorization: $EC_SMOKE_TEST_LICENSE_ID" -o embedded-cluster-smoke-test-staging-app-ci.tgz

Happy debugging!

Signed-off-by: Evans Mungai <[email protected]>

emosbaugh · 2025-06-19T13:48:32Z

api/controllers/install/hostpreflight.go

+	// Calculate airgap storage space requirement (2x uncompressed size for controller nodes)
+	var controllerAirgapStorageSpace string
+	if c.airgapBundle != "" {
+		airgapInfo, err := airgap.AirgapInfoFromPath(c.airgapBundle)


could we move this to the flag parsing code in preRunInstall so it is only run once and fails much earlier? Then make airgapInfo a property of InstallController like airgapBundle.

This method gets called by postInstallRunHostPreflights which is a http request served by the controller. At which point does preRunInstall come in?

preRunInstall is called in the cli and stores properties for later use in the InstallCmdFlags struct. You can add an airgapInfo property and pass this to the api server and store it as a property similar to airgapBundle on the API and InstallController structs.

Signed-off-by: Evans Mungai <[email protected]>

…unt-when' of github.com:replicatedhq/embedded-cluster into evansmungai/sc-123579/take-airgap-bundle-size-into-account-when

Signed-off-by: Evans Mungai <[email protected]>

…/take-airgap-bundle-size-into-account-when

emosbaugh · 2025-06-24T12:45:26Z

api/internal/managers/infra/install.go

+	var airgapInfo *kotsv1beta1.Airgap
+	if m.airgapBundle != "" {
+		var err error
+		airgapInfo, err = airgap.AirgapInfoFromPath(m.airgapBundle)
+		if err != nil {
+			return fmt.Errorf("failed to get airgap info: %w", err)
+		}
+	}
+


Can you follow the same pattern described here where you make airgapInfo a property of the manager and pass it with the function WithAirgapInfo?

emosbaugh · 2025-06-24T12:49:17Z

cmd/installer/cli/install.go

+			if flags.airgapBundle != "" {
+				var err error
+				airgapInfo, err = airgap.AirgapInfoFromPath(flags.airgapBundle)
+				if err != nil {
+					return fmt.Errorf("failed to get airgap info: %w", err)
+				}
+			}


Is there any reason this is not in the preRunInstall function as suggested? That way it exists with the rest of the flag parsing code and will work for both install and install run-preflights command.

Isn't InstallCmdFlags meant for CLI flags? That's why I did not move the new flag there.

I'll create a new flag like the rest

emosbaugh · 2025-06-24T12:49:53Z

cmd/installer/cli/install.go

@@ -426,6 +435,7 @@ func runManagerExperienceInstall(ctx context.Context, flags InstallCmdFlags, rc
 		ManagerPort:   flags.managerPort,
 		License:       flags.licenseBytes,
 		AirgapBundle:  flags.airgapBundle,
+		AirgapInfo:    airgapInfo,


Is there some reason you chose not to make airgapInfo a property of InstallCmdFlags as suggested? That way you will be following the existing pattern and dont have to pass it as an additional argument to many functions.

emosbaugh · 2025-06-24T12:52:23Z

cmd/installer/cli/install_runpreflights.go

+			if flags.airgapBundle != "" {
+				var err error
+				airgapInfo, err = airgap.AirgapInfoFromPath(flags.airgapBundle)
+				if err != nil {
+					return fmt.Errorf("failed to get airgap info: %w", err)
+				}
+			}


Move this to preRunInstall

emosbaugh · 2025-06-24T12:53:16Z

cmd/installer/cli/restore.go

+		// read file from path
+		var err error
+		airgapInfo, err = airgap.AirgapInfoFromPath(flags.airgapBundle)
+		if err != nil {
+			return fmt.Errorf("failed to get airgap bundle versions: %w", err)
+		}


Move this to preRunInstall

emosbaugh · 2025-06-24T12:54:30Z

api/internal/managers/infra/install.go

@@ -218,21 +228,28 @@ func (m *infraManager) installK0s(ctx context.Context, rc runtimeconfig.RuntimeC
 	return k0sCfg, nil
 }

-func (m *infraManager) recordInstallation(ctx context.Context, kcli client.Client, license *kotsv1beta1.License, rc runtimeconfig.RuntimeConfig) (*ecv1beta1.Installation, error) {
+func (m *infraManager) recordInstallation(ctx context.Context, kcli client.Client, license *kotsv1beta1.License, rc runtimeconfig.RuntimeConfig, airgapInfo *kotsv1beta1.Airgap) (*ecv1beta1.Installation, error) {


this will no longer need to be an argument as infraManager will have a property airgapInfo

…/take-airgap-bundle-size-into-account-when Signed-off-by: Evans Mungai <[email protected]>

Signed-off-by: Evans Mungai <[email protected]>

sgalsaleh · 2025-06-24T14:41:18Z

api/internal/managers/infra/install.go

@@ -98,6 +99,14 @@ func (m *infraManager) install(ctx context.Context, rc runtimeconfig.RuntimeConf
 		return fmt.Errorf("parse license: %w", err)
 	}

+	if m.airgapBundle != "" {
+		var err error
+		m.airgapInfo, err = airgap.AirgapInfoFromPath(m.airgapBundle)


this is passed to the api though, why extract it from the bundle again?

it makes it hard to test the api without an airgap bundle

That's a good call out. The API server has the struct, so it can be passed down to the manager from the controller.

Signed-off-by: Evans Mungai <[email protected]>

Add airgap bundle size to Installation CRD

0b06490

Signed-off-by: Evans Mungai <[email protected]>

github-actions bot added the type::feature label Jun 18, 2025

banjoh marked this pull request as draft June 18, 2025 12:19

Generate operator CRDs

e270d49

Signed-off-by: Evans Mungai <[email protected]>

banjoh added 5 commits June 18, 2025 18:41

Create airgapinfo package to parse airgap bundle metadata

d54331b

Signed-off-by: Evans Mungai <[email protected]>

Store airgap bundle size in Installation custom resource

2143149

Signed-off-by: Evans Mungai <[email protected]>

Add airgap storage space to host preflights for controller nodes

668b930

Signed-off-by: Evans Mungai <[email protected]>

Add controller airgap storage space calculation

473f5e1

Signed-off-by: Evans Mungai <[email protected]>

Separate airgap storage space preflight for controller and worker nodes

46ca2d3

Signed-off-by: Evans Mungai <[email protected]>

banjoh marked this pull request as ready for review June 19, 2025 12:58

emosbaugh requested changes Jun 19, 2025

View reviewed changes

banjoh added 2 commits June 19, 2025 15:19

Extract airgap.yaml once

b88f435

Signed-off-by: Evans Mungai <[email protected]>

Fix failing tests

5e53eca

Signed-off-by: Evans Mungai <[email protected]>

banjoh force-pushed the evansmungai/sc-123579/take-airgap-bundle-size-into-account-when branch 2 times, most recently from 520aa03 to 5e53eca Compare June 19, 2025 17:06

banjoh added 14 commits June 19, 2025 18:07

Add airgap bundle size to Installation CRD

9911048

Signed-off-by: Evans Mungai <[email protected]>

Generate operator CRDs

3fff57f

Signed-off-by: Evans Mungai <[email protected]>

Create airgapinfo package to parse airgap bundle metadata

a1e8816

Signed-off-by: Evans Mungai <[email protected]>

Store airgap bundle size in Installation custom resource

a3d3847

Signed-off-by: Evans Mungai <[email protected]>

Add airgap storage space to host preflights for controller nodes

367c093

Signed-off-by: Evans Mungai <[email protected]>

Add controller airgap storage space calculation

69038ae

Signed-off-by: Evans Mungai <[email protected]>

Separate airgap storage space preflight for controller and worker nodes

a1e0ee4

Signed-off-by: Evans Mungai <[email protected]>

Extract airgap.yaml once

ee7964f

Signed-off-by: Evans Mungai <[email protected]>

Fix failing tests

d93f5cf

Signed-off-by: Evans Mungai <[email protected]>

Merge branch 'evansmungai/sc-123579/take-airgap-bundle-size-into-acco…

8691b79

…unt-when' of github.com:replicatedhq/embedded-cluster into evansmungai/sc-123579/take-airgap-bundle-size-into-account-when

Comment out CI jobs

fb4f1b5

Signed-off-by: Evans Mungai <[email protected]>

Fix imports

05f7910

Signed-off-by: Evans Mungai <[email protected]>

Revert ci.yaml

fc96cf4

Signed-off-by: Evans Mungai <[email protected]>

Pass airgap info to the api

30e78de

Signed-off-by: Evans Mungai <[email protected]>

Merge remote-tracking branch 'origin/main' into evansmungai/sc-123579…

f72e05c

…/take-airgap-bundle-size-into-account-when

emosbaugh requested changes Jun 24, 2025

View reviewed changes

banjoh added 3 commits June 24, 2025 15:14

Move airgapInfo to preRunInstall

5206aab

Merge remote-tracking branch 'origin/main' into evansmungai/sc-123579…

5235538

…/take-airgap-bundle-size-into-account-when Signed-off-by: Evans Mungai <[email protected]>

A few more refactorings

00f00dc

Signed-off-by: Evans Mungai <[email protected]>

sgalsaleh reviewed Jun 24, 2025

View reviewed changes

Pass airgap info to infra manager

9f3562b

Signed-off-by: Evans Mungai <[email protected]>

emosbaugh approved these changes Jun 24, 2025

View reviewed changes

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What this PR does / why we need it:

Pending tasks

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Does this PR require documentation?

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