2 Commits

Author SHA1 Message Date
tomnewton-mulga 6389b37433 fix(gpu): Blackwell GPU support fixes for EKS/ECS image builds and VFIO (#559)
* fix(eks): GPU node AMI declares uefi boot mode

The spinifex-eks-node-gpu catalog entry declared BootMode: bios, but
the Ubuntu 26.04 GPU appliance image is built GPT/EFI-only. Under
legacy BIOS no OVMF/pflash firmware is attached, so the guest hangs at
firmware with zero serial console output.

* fix(images): install open-kernel NVIDIA DKMS driver for Blackwell GPUs

Blackwell-generation GPUs (e.g. RTX Pro 6000 Blackwell) refuse to
initialize under the closed/proprietary kernel module: dmesg shows
RmInitAdapter failing with "requires use of the NVIDIA open kernel
modules" (NVRM error 0x22). Switch from nvidia-dkms-<ver>-server to
nvidia-dkms-<ver>-server-open in both the shared ubuntu-gpu-nvidia
recipe and its verbatim duplicate in eks-node-gpu. nvidia-utils has no
separate open variant (userspace tools only), so it is unchanged.

* fix(eks): tolerate CP and GPU taints in ebs-csi-controller/lbc addons

A cluster with a GPU-only nodegroup has no untainted node: the CP
carries CriticalAddonsOnly (EKS parity keeps user workloads off it)
and every worker carries nvidia.com/gpu. Without tolerations for both,
ebs-csi-controller and aws-load-balancer-controller have nowhere to
schedule and stay Pending forever. Real EKS never needs this since its
control plane isn't a schedulable node, so the stock upstream
manifests carry no such toleration.

* fix(images): give the libguestfs appliance a working resolver

The guest's /etc/resolv.conf symlinks to systemd-resolved's stub
(127.0.0.53), which isn't running inside the appliance chroot, so DNS
is dead until package installs need it. Point it at a real resolver
before package installs, then restore the stub symlink afterward so
the shipped AMI still gets its DNS from systemd-resolved at boot like
a stock cloud image.

* fix(gpu): skip upstream PCIe bridge devices during VFIO bind/unbind

A GPU's IOMMU group can include an upstream PCIe bridge when the
platform lacks ACS isolation between them. vfio-pci refuses to bind
non-endpoint bridge devices, so Claim/ReclaimByAddress must filter
bridge-class (0x06) members out of the group before touching driver
bindings, rather than failing the whole claim or leaving the bridge
rebound incorrectly.

* fix(ecs): GPU node AMI declares uefi boot mode

The spinifex-ecs-node-gpu catalog entry declared BootMode: bios, but the
Ubuntu 26.04 GPU appliance image is built GPT/EFI-only. Under legacy BIOS
no OVMF/pflash firmware is attached, so the guest hangs at firmware with
zero serial console output.

Same defect and same fix as the eks-node-gpu entry: both images are built
by the same script from the same stock Ubuntu cloudimg, so both were
EFI-only and only one was corrected.

* fix(images): open-kernel NVIDIA module on ecs-agent-gpu, pin driver branch

ecs-agent-gpu still installed nvidia-dkms-<N>-server, the proprietary
kernel module. NVIDIA ships no proprietary module for Blackwell (GB202)
and later, so ECS GPU container-instances could not bind those cards on
any driver branch. It is the third verbatim copy of the routine and was
missed when the other two were fixed.

Also pins the driver branch across all three copies. The branch was
resolved at build time via apt-cache search | sort -rn | head -1, which
sorts on the number in the package name — but that number is a branch
alias, not a driver version (nvidia-dkms-535-server installs 580.126.20),
so the ordering key need not match what installs. Resolving also let
identical source produce different drivers on different days.

The pin lives in setup.sh rather than manifest.conf because manifest
variables are not passed into the guest: the setup script is uploaded and
executed by virt-customize --run, with no environment carried across.

* fix(eks): tolerate CP and GPU taints in argocd addon

All six argocd Deployments and its StatefulSet carried no tolerations. A
cluster with a GPU-only nodegroup has no untainted node to place them on:
the control plane carries CriticalAddonsOnly and every worker carries
nvidia.com/gpu, so the pods stay Pending forever.

Same defect the ebs-csi-controller and load-balancer-controller addons
already had. Real EKS never hits it because its control plane is not a
schedulable node, so the stock upstream manifests carry no such
toleration and the divergence is ours to maintain.

---------

Co-authored-by: joshsiv-mulga <mrk@mulgadc.com>
2026-07-27 12:11:18 +10:00
Josh Siviour bc9556d1a9 fix(eks): managed-CP worker data-plane — apiserver reachability, node-local CoreDNS, SG teardown (#368)
* fix: persist instance TagSpecifications in RunInstance

RunInstance built the ec2.Instance metadata but never read
input.TagSpecifications, so DescribeInstances returned untagged
instances and tag filters matched nothing. EKS node groups discover
their workers by the spinifex:eks-cluster / spinifex:eks-nodegroup
tags, so scale-up convergence and worker reconciliation depended on
tags that were silently dropped.

Apply instance-scoped TagSpecifications onto the built instance so the
tags surface through DescribeInstances and tag filters.

* fix: serialize nodegroup reconcile via CAS to prevent scale overshoot

UpdateNodegroupConfig is dispatched on a queue group, so two
overlapping requests (e.g. an SDK retry mid-flight) each read
current = len(InstanceIDs) and each launched desired-current workers,
overshooting the target (1 -> 5 for desired=3) and stranding untracked
VMs via last-writer-wins on the unconditional PutNodegroupRecord.

Make every durable nodegroup-record mutation a compare-and-swap on the
KV revision. Scale-up launches one worker at a time and CAS-appends it
only while the record is below the live ScalingDesired, terminating any
surplus VM launched into an already-full record. Scale-down terminates
before the CAS truncation so a crash or retry leaves reclaimable dead
IDs rather than orphaned VMs. A concurrent regression test asserts two
overlapping scale-ups converge to exactly desired under -race.

* fix: return securityGroupRuleSet from AuthorizeSecurityGroup ingress/egress

The AWS provider's aws_vpc_security_group_ingress_rule reads
SecurityGroupRules[0].SecurityGroupRuleId on create; an empty ruleset
panics the plugin (Plugin did not respond), though the rule applies
server-side. Echo the created rules via sgRuleToSecurityGroupRule, the
same shape DescribeSecurityGroupRules already returns.

* fix: surface InsufficientInstanceCapacity from nodegroup scale, not 500

launchWorkersCAS wrapped the bare awserror code via fmt.Errorf, so the
gateway ErrorHandler's exact-match against ErrorLookup missed and remapped
to InternalError (500). An out-of-capacity scale now surfaces the real
InsufficientInstanceCapacity code (400); opaque internal failures still
wrap and stay 500. Adds awserrors.HasErrorCode for the membership test.

* fix: cut EKS node boot ~50s — drop cloud-final deadlock + syslinux menu

Worker/server user-data runcmd ended with `[ rc-service, local, start ]`,
which runs inside cloud-final while the OpenRC `local` service is ordered
after it — a deadlock broken only by OpenRC's ~50s start timeout, stalling
the k3s join. Run the IMDS route script directly instead and keep
`rc-update add local default` for reboot persistence.

setup.sh: cut the SYSLINUX boot-menu countdown 10s->~1s (kept nonzero so the
menu stays interruptible over serial).

Validated live on env19 CP: boot menu 1s, no `waiting for cloud-final`
stall, apiserver ready ~66s (was ~109s+).

mulga-siv-332

* feat: add argocd managed addon + bake bundle into eks-node AMI

The addon catalog advertised coredns and aws-load-balancer-controller, but
the only baked manifest shipped in the eks-node AMI was the spinifex-noop
fixture. Installing any real addon failed with 'no baked bundle for version'
once the VM-side renderer found nothing on disk.

Add argocd v3.0.23 as a real, demonstrable managed addon: catalog entry (no
IRSA), a flattened namespaced install manifest baked into the AMI, and the
manifest.conf bake line. The eks-addons-access workbook switches from coredns
(redundant on K3s, never baked) to argocd.

The baked bundle is generated from upstream install.yaml via kubectl kustomize
with namespace: argocd plus a prepended Namespace, since upstream is
namespace-agnostic and K3s auto-deploy applies with no -n flag.

* fix(eks): run CoreDNS as a node-local DaemonSet for worker DNS

k3s ships CoreDNS as a single-replica Deployment that tolerates the CP taint
and strands itself on the control-plane node. In the managed-CP topology the
worker<->CP pod overlay cannot cross the VPC boundary, so worker pods cannot
reach a CP-resident CoreDNS and lose all cluster + external DNS.

Skip the bundled CoreDNS (coredns.yaml.skip, staged in k3s.initd like traefik)
and deploy a Mulga-owned variant: a DaemonSet (one pod per node) plus kube-dns
internalTrafficPolicy=Local, so every node resolves via its own CoreDNS. Immune
to the cross-VPC overlay gap and topology-agnostic (single-node and managed-CP
both work). Image-side only; no handler change.

* fix(eks): revoke cross-referencing SG rules before delete on teardown

DeleteClusterSGs deleted the control-plane and nodegroup SGs directly, but they
cross-reference each other (EnsureNodegroupSGRules), and AWS refuses to delete a
security group still referenced by another SG's rule. Both deletes failed with
DependencyViolation, the SGs leaked, and the VPC could not be deleted (tofu
destroy hung on DeleteVpc).

Resolve both SG IDs, revoke all ingress on each to break the cp<->ng cycle, then
delete both. Adds RevokeSecurityGroupIngress to sgProvisioner (already on
VPCServiceImpl) and revokeAllSGIngress, with a regression test that models AWS's
DependencyViolation.

* fix(eks): advertise NLB front-end so worker pods reach the apiserver ClusterIP

In the managed-control-plane topology the apiserver advertised its Set-B
node-ip into the in-cluster `kubernetes` Endpoints. That IP lives in the
unpeered CP VPC and is unreachable from worker pods, so every worker pod
using the apiserver ClusterIP (CoreDNS kubernetes-plugin sync, controllers,
argocd redis secret-init) failed.

- k3s_server_vm.go: set advertise-address to the worker-reachable NLB
  front-end (PrivateEndpointIP, else EndpointIP); both are already cert SANs.
- nlb.go: add a second :6443 listener on the cluster NLB (same CP target
  group) so PrivateEndpointIP:6443 — the advertised endpoint — is served.
- security_groups.go: admit :6443 on the private-endpoint SG.

Validated on a live managed-CP cluster: worker CoreDNS /ready 200, all argocd
pods Running, kubectl logs on worker pods working.
2026-06-16 20:27:21 +10:00