From 33be713d0ceb7463c4071dc9157843582295026c Mon Sep 17 00:00:00 2001
From: Michal <michal@itaz.eu>
Date: Fri, 14 Aug 2026 23:22:14 +0100
Subject: [PATCH] feat(bastion): size the rancher LV at 120G for k8s roles in
 kickstart
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The 20G /var/lib/rancher LV (k3s imageFs) idled at 85% used from
steady-state images alone; one ~5G image pull tripped imagefs eviction
and evicted unrelated pods (2026-08-14 DiskPressure incident). Create
the LV for both worker and infra roles at 120G — it must be sized here
because longhorn's --grow consumes all remaining VG space, making
post-install lvextend impossible.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_017f6jyeeDqP4ufyeL3UER9w
---
 bastion/src/bastion/src/templates/install.ks.ts | 11 ++++++++---
 bastion/src/bastion/tests/kickstart.test.ts     | 14 +++++++++-----
 2 files changed, 17 insertions(+), 8 deletions(-)

diff --git a/bastion/src/bastion/src/templates/install.ks.ts b/bastion/src/bastion/src/templates/install.ks.ts
index 94af999..87229cf 100644
--- a/bastion/src/bastion/src/templates/install.ks.ts
+++ b/bastion/src/bastion/src/templates/install.ks.ts
@@ -40,6 +40,11 @@ export function renderInstallKickstart(params: InstallKickstartParams): string {
   const now = new Date().toISOString();
   const hasLonghorn = role === "worker";
   const hasRancher = role === "infra";
+  // k8s roles get a dedicated 120G image-store LV. 2026-08 incident: the old
+  // 20G LV idled at 85% used, so a single ~5G image pull tripped imagefs
+  // eviction. Must be sized here — longhorn's --grow consumes all remaining
+  // VG space, making post-install lvextend impossible on worker nodes.
+  const hasRancherLv = role === "infra" || role === "worker";
   const isVanilla = role === "vanilla";
 
   // -- Auth section --
@@ -113,9 +118,9 @@ done
     ? `logvol /var/lib/longhorn --vgname=${vg} --name=longhorn --fstype=xfs --grow --size=1`
     : "";
 
-  // -- Rancher LV for fresh install (infra role) --
-  const rancherFreshLine = hasRancher
-    ? `logvol /var/lib/rancher --vgname=${vg} --name=rancher --fstype=xfs --size=20480`
+  // -- Rancher LV for fresh install (k8s roles: worker + infra) --
+  const rancherFreshLine = hasRancherLv
+    ? `logvol /var/lib/rancher --vgname=${vg} --name=rancher --fstype=xfs --size=122880`
     : "";
 
   return `# Lab Bastion -- Fedora ${fedoraVersion} server install
diff --git a/bastion/src/bastion/tests/kickstart.test.ts b/bastion/src/bastion/tests/kickstart.test.ts
index 771f5d1..5a5dada 100644
--- a/bastion/src/bastion/tests/kickstart.test.ts
+++ b/bastion/src/bastion/tests/kickstart.test.ts
@@ -96,9 +96,9 @@ describe("renderInstallKickstart", () => {
     expect(ks).toContain("/api/progress");
   });
 
-  it("infra role has /var/lib/rancher partition", () => {
+  it("infra role has 120G /var/lib/rancher partition", () => {
     const ks = renderInstallKickstart(baseParams({ role: "infra" }));
-    expect(ks).toContain("logvol /var/lib/rancher --vgname=labvg --name=rancher --fstype=xfs --size=20480");
+    expect(ks).toContain("logvol /var/lib/rancher --vgname=labvg --name=rancher --fstype=xfs --size=122880");
   });
 
   it("infra role has k3s install", () => {
@@ -106,10 +106,14 @@ describe("renderInstallKickstart", () => {
     expect(ks).toContain("curl -sfL https://get.k3s.io | INSTALL_K3S_SKIP_START=true sh -");
   });
 
-  it("worker role does NOT have /var/lib/rancher partition in fresh install", () => {
+  it("worker role has 120G /var/lib/rancher partition (imageFs must be sized before longhorn --grow)", () => {
     const ks = renderInstallKickstart(baseParams({ role: "worker" }));
-    // Worker should not have the fresh-install rancher partition line
-    expect(ks).not.toContain("logvol /var/lib/rancher --vgname=labvg --name=rancher --fstype=xfs --size=20480");
+    expect(ks).toContain("logvol /var/lib/rancher --vgname=labvg --name=rancher --fstype=xfs --size=122880");
+  });
+
+  it("vanilla role does NOT have /var/lib/rancher partition in fresh install", () => {
+    const ks = renderInstallKickstart(baseParams({ role: "vanilla" }));
+    expect(ks).not.toContain("--name=rancher --fstype=xfs");
   });
 
   it("worker role does NOT have k3s install", () => {