internal/bootstrap/bootstrap.go

@@ -45,6 +45,12 @@ type operationalSecrets struct {
 
 var initializeOpenBao = openbao.Initialize
 
+var readOpenBaoRecovery = openbao.ReadRecoveryMaterial
+
+var decryptGeneratedSOPS = decryptSOPSFile
+
+var writeGeneratedSOPS = writeSOPSEncryptedFile
+
 var ensureForgejoWebhook = func(cfg config.Config, repo, webhookURL, authorization string) error {
 	manager := forgejo.NewRepoManager(cfg.Git.BaseURL, cfg.Git.Token, cfg.Git.Owner, cfg.Git.Username, cfg.Flux.ManifestsRepo, cfg.Flux.RepoName, cfg.Flux.Branch, "maidn/bootstrap-"+cfg.ClusterID)
 	return manager.EnsureWebhook(repo, webhookURL, authorization)
@@ -84,8 +90,8 @@ func (r Runner) Run() error {
 		if _, err := os.Stat(r.Config.SOPS.OperationalSecretsPath); err != nil {
 			return fmt.Errorf("preflight operational SOPS secrets: %w", err)
 		}
-		if r.Config.SOPS.RecoveryRecipient == "" || r.Config.SOPS.RecoveryIdentityPath == "" || r.Config.SOPS.RecoveryBundlePath == "" {
-			return errors.New("SOPS recoveryRecipient, recoveryIdentityPath, and recoveryBundlePath are required")
+		if r.Config.SOPS.RecoveryRecipient == "" {
+			return errors.New("SOPS recoveryRecipient is required")
 		}
 	}
 	if r.Mode == "" {
@@ -100,6 +106,15 @@ func (r Runner) Run() error {
 	if r.RegisterWebhook {
 		return r.reconcileWebhook(filepath.Join(r.Config.Git.CloneParent, r.Config.Talos.RepoDirName, r.Config.Talos.GeneratedDir))
 	}
+	if r.Config.SOPS.RecoveryIdentityPath == "" || r.Config.SOPS.RecoveryBundlePath == "" {
+		return errors.New("SOPS recoveryIdentityPath and recoveryBundlePath are required")
+	}
+	if _, err := os.Stat(r.Config.SOPS.RecoveryIdentityPath); err != nil {
+		return fmt.Errorf("preflight OpenBao recovery identity: %w", err)
+	}
+	if _, err := os.Stat(r.Config.SOPS.RecoveryBundlePath); err != nil {
+		return fmt.Errorf("preflight OpenBao recovery bundle: %w", err)
+	}
 	workspace := r.Config.WorkspaceDir
 	if err := EnsureTemplateRevisions(r.Config); err != nil {
 		return err
@@ -167,6 +182,13 @@ func (r Runner) Run() error {
 			if err := writeDemocraticCSISecret(filepath.Join(dir, "base", "democratic-csi", "secret.sops.yaml"), r.Config.DemocraticCSI, r.Config.SOPS.AgeKeyPath); err != nil {
 				return err
 			}
+			openbaoDir := filepath.Join(dir, "base", "openbao")
+			if err := writeOpenBaoUnsealSecret(filepath.Join(openbaoDir, "unseal.sops.yaml"), r.Config.SOPS.RecoveryIdentityPath, r.Config.SOPS.RecoveryBundlePath, r.Config.SOPS.AgeKeyPath); err != nil {
+				return err
+			}
+			if err := ensureOpenBaoUnsealKustomization(filepath.Join(openbaoDir, "kustomization.yaml")); err != nil {
+				return err
+			}
 			if err := ensureClusterKustomizations(clusterDir); err != nil {
 				return err
 			}
@@ -325,6 +347,96 @@ func writeDemocraticCSISecret(path string, csi config.DemocraticCSIConfig, ageKe
 	return writeSOPSEncryptedFile(path, ageKeyPath, plaintext)
 }
 
+func writeOpenBaoUnsealSecret(path, recoveryIdentityPath, recoveryBundlePath, ageKeyPath string) error {
+	material, err := readOpenBaoRecovery(recoveryIdentityPath, recoveryBundlePath)
+	if err != nil {
+		return fmt.Errorf("read OpenBao recovery material: %w", err)
+	}
+	plaintext, err := renderOpenBaoUnsealSecret(material)
+	if err != nil {
+		return err
+	}
+	if _, err := os.Stat(path); err == nil {
+		existing, err := decryptGeneratedSOPS(path, ageKeyPath)
+		if err != nil {
+			return fmt.Errorf("decrypt existing OpenBao unseal secret: %w", err)
+		}
+		if sameYAML(existing, plaintext) {
+			return nil
+		}
+	} else if !os.IsNotExist(err) {
+		return err
+	}
+	return writeGeneratedSOPS(path, ageKeyPath, plaintext)
+}
+
+func renderOpenBaoUnsealSecret(material openbao.RecoveryMaterial) ([]byte, error) {
+	if material.RootToken == "" || material.UnsealThreshold < 1 || len(material.UnsealKeysB64) < material.UnsealThreshold {
+		return nil, errors.New("OpenBao recovery material is incomplete")
+	}
+	data := map[string]string{"root-token": material.RootToken}
+	for index, share := range material.UnsealKeysB64 {
+		if share == "" {
+			return nil, errors.New("OpenBao recovery material contains an invalid unseal key")
+		}
+		data[fmt.Sprintf("unseal-%d", index+1)] = share
+	}
+	return yaml.Marshal(struct {
+		APIVersion string            `yaml:"apiVersion"`
+		Kind       string            `yaml:"kind"`
+		Metadata   map[string]string `yaml:"metadata"`
+		Type       string            `yaml:"type"`
+		StringData map[string]string `yaml:"stringData"`
+	}{
+		APIVersion: "v1",
+		Kind:       "Secret",
+		Metadata:   map[string]string{"name": "openbao-unseal", "namespace": "openbao"},
+		Type:       "Opaque",
+		StringData: data,
+	})
+}
+
+func ensureOpenBaoUnsealKustomization(path string) error {
+	content, err := os.ReadFile(path)
+	if err != nil {
+		return err
+	}
+	var document struct {
+		APIVersion string   `yaml:"apiVersion"`
+		Kind       string   `yaml:"kind"`
+		Resources  []string `yaml:"resources"`
+	}
+	decoder := yaml.NewDecoder(bytes.NewReader(content))
+	if err := decoder.Decode(&document); err != nil {
+		return fmt.Errorf("parse OpenBao Kustomization: %w", err)
+	}
+	if err := decoder.Decode(&struct{}{}); !errors.Is(err, io.EOF) {
+		return errors.New("OpenBao Kustomization must contain one YAML document")
+	}
+	if document.APIVersion != "kustomize.config.k8s.io/v1beta1" || document.Kind != "Kustomization" || len(document.Resources) == 0 {
+		return errors.New("OpenBao Kustomization must define resources")
+	}
+	count := 0
+	for _, resource := range document.Resources {
+		if resource == "" {
+			return errors.New("OpenBao Kustomization contains an empty resource")
+		}
+		if resource == "unseal.sops.yaml" {
+			count++
+		}
+	}
+	if count > 1 {
+		return errors.New("OpenBao Kustomization references unseal.sops.yaml more than once")
+	}
+	if count == 1 {
+		return nil
+	}
+	if !bytes.HasSuffix(content, []byte("\n")) {
+		content = append(content, '\n')
+	}
+	return os.WriteFile(path, append(content, []byte("  - unseal.sops.yaml\n")...), 0644)
+}
+
 func WriteOperationalSecrets(path, ageKeyPath string, secrets map[string]map[string]string) error {
 	plaintext, err := yaml.Marshal(operationalSecrets{Secrets: secrets})
 	if err != nil {

internal/bootstrap/bootstrap_test.go

@@ -15,6 +15,8 @@ import (
 
 	"github.com/Pingu-Studio/MaidnCLI/internal/config"
 	"github.com/Pingu-Studio/MaidnCLI/internal/forgejo"
+	"github.com/Pingu-Studio/MaidnCLI/internal/openbao"
+	"gopkg.in/yaml.v3"
 )
 
 func TestRenderCiliumConfig(t *testing.T) {
@@ -180,6 +182,121 @@ func TestWriteDemocraticCSISecretEncryptsValues(t *testing.T) {
 	}
 }
 
+func TestWriteOpenBaoUnsealSecretRendersRecoveryMaterial(t *testing.T) {
+	originalRead := readOpenBaoRecovery
+	originalWrite := writeGeneratedSOPS
+	t.Cleanup(func() {
+		readOpenBaoRecovery = originalRead
+		writeGeneratedSOPS = originalWrite
+	})
+	readOpenBaoRecovery = func(identityPath, bundlePath string) (openbao.RecoveryMaterial, error) {
+		if identityPath != "recovery-identity" || bundlePath != "recovery-bundle" {
+			t.Fatal("OpenBao recovery paths were not passed to the decryption boundary")
+		}
+		return openbao.RecoveryMaterial{RootToken: "test-root", UnsealThreshold: 2, UnsealKeysB64: []string{"test-share-1", "test-share-2", "test-share-3"}}, nil
+	}
+	var rendered []byte
+	writeGeneratedSOPS = func(path, ageKeyPath string, plaintext []byte) error {
+		if ageKeyPath != "flux-age-identity" {
+			t.Fatal("OpenBao unseal secret used the wrong Flux age identity")
+		}
+		rendered = append([]byte(nil), plaintext...)
+		return os.WriteFile(path, []byte("sops: {}\n"), 0600)
+	}
+
+	if err := writeOpenBaoUnsealSecret(filepath.Join(t.TempDir(), "unseal.sops.yaml"), "recovery-identity", "recovery-bundle", "flux-age-identity"); err != nil {
+		t.Fatal(err)
+	}
+	var secret struct {
+		Metadata   map[string]string `yaml:"metadata"`
+		StringData map[string]string `yaml:"stringData"`
+	}
+	if err := yaml.Unmarshal(rendered, &secret); err != nil || secret.Metadata["name"] != "openbao-unseal" || secret.Metadata["namespace"] != "openbao" || len(secret.StringData) != 4 || secret.StringData["root-token"] == "" || secret.StringData["unseal-3"] == "" {
+		t.Fatal("OpenBao unseal Secret was not rendered")
+	}
+}
+
+func TestWriteOpenBaoUnsealSecretIsIdempotent(t *testing.T) {
+	originalRead := readOpenBaoRecovery
+	originalDecrypt := decryptGeneratedSOPS
+	originalWrite := writeGeneratedSOPS
+	t.Cleanup(func() {
+		readOpenBaoRecovery = originalRead
+		decryptGeneratedSOPS = originalDecrypt
+		writeGeneratedSOPS = originalWrite
+	})
+	material := openbao.RecoveryMaterial{RootToken: "test-root", UnsealThreshold: 2, UnsealKeysB64: []string{"test-share-1", "test-share-2"}}
+	plaintext, err := renderOpenBaoUnsealSecret(material)
+	if err != nil {
+		t.Fatal(err)
+	}
+	readOpenBaoRecovery = func(string, string) (openbao.RecoveryMaterial, error) { return material, nil }
+	decryptGeneratedSOPS = func(string, string) ([]byte, error) { return plaintext, nil }
+	writes := 0
+	writeGeneratedSOPS = func(string, string, []byte) error {
+		writes++
+		return nil
+	}
+	path := filepath.Join(t.TempDir(), "unseal.sops.yaml")
+	if err := os.WriteFile(path, []byte("sops: {}\n"), 0600); err != nil {
+		t.Fatal(err)
+	}
+	if err := writeOpenBaoUnsealSecret(path, "recovery-identity", "recovery-bundle", "flux-age-identity"); err != nil {
+		t.Fatal(err)
+	}
+	if writes != 0 {
+		t.Fatal("matching OpenBao unseal Secret was re-encrypted")
+	}
+}
+
+func TestWriteOpenBaoUnsealSecretRejectsUnreadableExistingSecret(t *testing.T) {
+	originalRead := readOpenBaoRecovery
+	originalDecrypt := decryptGeneratedSOPS
+	originalWrite := writeGeneratedSOPS
+	t.Cleanup(func() {
+		readOpenBaoRecovery = originalRead
+		decryptGeneratedSOPS = originalDecrypt
+		writeGeneratedSOPS = originalWrite
+	})
+	readOpenBaoRecovery = func(string, string) (openbao.RecoveryMaterial, error) {
+		return openbao.RecoveryMaterial{RootToken: "test-root", UnsealThreshold: 1, UnsealKeysB64: []string{"test-share"}}, nil
+	}
+	decryptGeneratedSOPS = func(string, string) ([]byte, error) { return nil, errors.New("unavailable") }
+	writes := 0
+	writeGeneratedSOPS = func(string, string, []byte) error {
+		writes++
+		return nil
+	}
+	path := filepath.Join(t.TempDir(), "unseal.sops.yaml")
+	if err := os.WriteFile(path, []byte("sops: {}\n"), 0600); err != nil {
+		t.Fatal(err)
+	}
+	if err := writeOpenBaoUnsealSecret(path, "recovery-identity", "recovery-bundle", "flux-age-identity"); err == nil || writes != 0 {
+		t.Fatal("unreadable OpenBao unseal Secret was overwritten")
+	}
+}
+
+func TestEnsureOpenBaoUnsealKustomizationIsIdempotent(t *testing.T) {
+	path := filepath.Join(t.TempDir(), "kustomization.yaml")
+	if err := os.WriteFile(path, []byte("apiVersion: kustomize.config.k8s.io/v1beta1\nkind: Kustomization\nresources:\n  - namespace.yaml\n"), 0644); err != nil {
+		t.Fatal(err)
+	}
+	if err := ensureOpenBaoUnsealKustomization(path); err != nil {
+		t.Fatal(err)
+	}
+	first, err := os.ReadFile(path)
+	if err != nil {
+		t.Fatal(err)
+	}
+	if err := ensureOpenBaoUnsealKustomization(path); err != nil {
+		t.Fatal(err)
+	}
+	second, err := os.ReadFile(path)
+	if err != nil || !strings.Contains(string(first), "  - unseal.sops.yaml\n") || string(first) != string(second) {
+		t.Fatal("OpenBao Kustomization was not updated idempotently")
+	}
+}
+
 func TestNewWebhookAuthorization(t *testing.T) {
 	authorization, err := NewWebhookAuthorization()
 	if err != nil {

internal/openbao/bootstrap.go

@@ -3,7 +3,9 @@ package openbao
 import (
 	"bytes"
 	"encoding/json"
+	"errors"
 	"fmt"
+	"io"
 	"os"
 	"os/exec"
 	"path/filepath"
@@ -20,7 +22,7 @@ type status struct {
 	Sealed      bool `json:"sealed"`
 }
 
-type recovery struct {
+type RecoveryMaterial struct {
 	UnsealKeysB64   []string `json:"unseal_keys_b64"`
 	UnsealThreshold int      `json:"unseal_threshold"`
 	RootToken       string   `json:"root_token"`
@@ -30,6 +32,15 @@ type operationalSecrets struct {
 	Secrets map[string]map[string]string `yaml:"secrets"`
 }
 
+var decryptRecovery = func(identityPath, bundlePath string) ([]byte, error) {
+	cmd := exec.Command("age", "-d", "-i", identityPath, bundlePath)
+	output, err := cmd.Output()
+	if err != nil {
+		return nil, fmt.Errorf("decrypt OpenBao recovery material: %w", err)
+	}
+	return output, nil
+}
+
 func EnsureRecoveryIdentity(identityPath string) (string, error) {
 	if _, err := os.Stat(identityPath); os.IsNotExist(err) {
 		if err := os.MkdirAll(filepath.Dir(identityPath), 0700); err != nil {
@@ -62,26 +73,24 @@ func Initialize(kubeconfig, recipient, identityPath, bundlePath, ageKeyPath, ope
 	if err != nil {
 		return nil, err
 	}
-	var material recovery
+	var material RecoveryMaterial
 	if !current.Initialized {
 		output, err := execInPod(kubeconfig, nil, "bao", "operator", "init", "-format=json")
 		if err != nil {
 			return nil, fmt.Errorf("initialize OpenBao: %w", err)
 		}
-		if err := json.Unmarshal(output, &material); err != nil {
-			return nil, fmt.Errorf("parse OpenBao recovery material: %w", err)
+		material, err = parseRecoveryMaterial(output)
+		if err != nil {
+			return nil, err
 		}
 		if err := encryptRecovery(recipient, bundlePath, output); err != nil {
 			return nil, err
 		}
 	} else {
-		output, err := decryptRecovery(identityPath, bundlePath)
+		material, err = ReadRecoveryMaterial(identityPath, bundlePath)
 		if err != nil {
 			return nil, err
 		}
-		if err := json.Unmarshal(output, &material); err != nil {
-			return nil, fmt.Errorf("parse encrypted OpenBao recovery material: %w", err)
-		}
 	}
 	if current.Sealed {
 		if err := unseal(kubeconfig, material); err != nil {
@@ -146,6 +155,46 @@ func validateRecoveryRecipient(recipient, bundlePath string) error {
 	return nil
 }
 
+// ReadRecoveryMaterial decrypts and validates the local OpenBao recovery bundle.
+func ReadRecoveryMaterial(identityPath, bundlePath string) (RecoveryMaterial, error) {
+	plaintext, err := decryptRecovery(identityPath, bundlePath)
+	if err != nil {
+		return RecoveryMaterial{}, err
+	}
+	return parseRecoveryMaterial(plaintext)
+}
+
+func parseRecoveryMaterial(plaintext []byte) (RecoveryMaterial, error) {
+	var material RecoveryMaterial
+	decoder := json.NewDecoder(bytes.NewReader(plaintext))
+	if err := decoder.Decode(&material); err != nil {
+		return RecoveryMaterial{}, fmt.Errorf("parse OpenBao recovery material: %w", err)
+	}
+	if err := decoder.Decode(&struct{}{}); !errors.Is(err, io.EOF) {
+		return RecoveryMaterial{}, fmt.Errorf("OpenBao recovery material must contain one JSON document")
+	}
+	if material.RootToken == "" || strings.TrimSpace(material.RootToken) != material.RootToken {
+		return RecoveryMaterial{}, fmt.Errorf("OpenBao recovery material requires a root token")
+	}
+	if material.UnsealThreshold < 1 {
+		return RecoveryMaterial{}, fmt.Errorf("OpenBao recovery material requires a positive unseal threshold")
+	}
+	if len(material.UnsealKeysB64) < material.UnsealThreshold {
+		return RecoveryMaterial{}, fmt.Errorf("OpenBao recovery material contains fewer than %d unseal keys", material.UnsealThreshold)
+	}
+	seen := make(map[string]bool, len(material.UnsealKeysB64))
+	for _, key := range material.UnsealKeysB64 {
+		if key == "" || strings.TrimSpace(key) != key {
+			return RecoveryMaterial{}, fmt.Errorf("OpenBao recovery material contains an invalid unseal key")
+		}
+		if seen[key] {
+			return RecoveryMaterial{}, fmt.Errorf("OpenBao recovery material contains duplicate unseal keys")
+		}
+		seen[key] = true
+	}
+	return material, nil
+}
+
 func writeSecret(kubeconfig, rootToken, secretPath string, values map[string]string) error {
 	if !regexp.MustCompile(`^[a-z0-9][a-z0-9/_-]*$`).MatchString(secretPath) || len(values) == 0 {
 		return fmt.Errorf("invalid OpenBao secret path %q", secretPath)
@@ -200,15 +249,11 @@ func getStatus(kubeconfig string) (status, error) {
 	return current, nil
 }
 
-func unseal(kubeconfig string, material recovery) error {
-	threshold := material.UnsealThreshold
-	if threshold == 0 {
-		threshold = 3
+func unseal(kubeconfig string, material RecoveryMaterial) error {
+	if material.UnsealThreshold < 1 || len(material.UnsealKeysB64) < material.UnsealThreshold {
+		return fmt.Errorf("OpenBao recovery material has insufficient unseal keys")
 	}
-	if len(material.UnsealKeysB64) < threshold {
-		return fmt.Errorf("OpenBao recovery bundle contains fewer than %d unseal keys", threshold)
-	}
-	for _, key := range material.UnsealKeysB64[:threshold] {
+	for _, key := range material.UnsealKeysB64[:material.UnsealThreshold] {
 		if _, err := execInPod(kubeconfig, []byte(key+"\n"), "sh", "-ec", "read -r key; bao operator unseal \"$key\" >/dev/null"); err != nil {
 			return fmt.Errorf("unseal OpenBao: %w", err)
 		}
@@ -245,21 +290,12 @@ func encryptRecovery(recipient, bundlePath string, plaintext []byte) error {
 	}
 	cmd := exec.Command("age", "-r", recipient, "-o", bundlePath)
 	cmd.Stdin = bytes.NewReader(plaintext)
-	if output, err := cmd.CombinedOutput(); err != nil {
-		return fmt.Errorf("encrypt OpenBao recovery material: %w: %s", err, bytes.TrimSpace(output))
+	if _, err := cmd.CombinedOutput(); err != nil {
+		return fmt.Errorf("encrypt OpenBao recovery material: %w", err)
 	}
 	return os.Chmod(bundlePath, 0600)
 }
 
-func decryptRecovery(identityPath, bundlePath string) ([]byte, error) {
-	cmd := exec.Command("age", "-d", "-i", identityPath, bundlePath)
-	output, err := cmd.Output()
-	if err != nil {
-		return nil, fmt.Errorf("decrypt OpenBao recovery material: %w", err)
-	}
-	return output, nil
-}
-
 func execInPod(kubeconfig string, input []byte, args ...string) ([]byte, error) {
 	command := append([]string{"--kubeconfig", kubeconfig, "-n", "openbao", "exec", "-i", "openbao-0", "--"}, args...)
 	cmd := exec.Command("kubectl", command...)

internal/openbao/bootstrap_test.go

@@ -1,6 +1,7 @@
 package openbao
 
 import (
+	"errors"
 	"os/exec"
 	"path/filepath"
 	"strings"
@@ -19,3 +20,36 @@ func TestEnsureRecoveryIdentity(t *testing.T) {
 		t.Fatalf("invalid recovery recipient")
 	}
 }
+
+func TestReadRecoveryMaterialDecryptsAndValidatesBundle(t *testing.T) {
+	original := decryptRecovery
+	t.Cleanup(func() { decryptRecovery = original })
+	called := false
+	decryptRecovery = func(identityPath, bundlePath string) ([]byte, error) {
+		called = identityPath == "recovery-identity" && bundlePath == "recovery-bundle"
+		return []byte(`{"unseal_keys_b64":["test-share-1","test-share-2"],"unseal_threshold":2,"root_token":"test-root"}`), nil
+	}
+
+	material, err := ReadRecoveryMaterial("recovery-identity", "recovery-bundle")
+	if err != nil || !called || material.UnsealThreshold != 2 || len(material.UnsealKeysB64) != 2 || material.RootToken == "" {
+		t.Fatal("valid OpenBao recovery material was not read")
+	}
+}
+
+func TestReadRecoveryMaterialRejectsMalformedOrInsufficientBundle(t *testing.T) {
+	original := decryptRecovery
+	t.Cleanup(func() { decryptRecovery = original })
+	for _, plaintext := range [][]byte{
+		[]byte(`{"unseal_keys_b64":`),
+		[]byte(`{"unseal_keys_b64":["test-share"],"unseal_threshold":2,"root_token":"test-root"}`),
+	} {
+		decryptRecovery = func(string, string) ([]byte, error) { return plaintext, nil }
+		if _, err := ReadRecoveryMaterial("recovery-identity", "recovery-bundle"); err == nil {
+			t.Fatal("invalid OpenBao recovery material was accepted")
+		}
+	}
+	decryptRecovery = func(string, string) ([]byte, error) { return nil, errors.New("unavailable") }
+	if _, err := ReadRecoveryMaterial("recovery-identity", "recovery-bundle"); err == nil {
+		t.Fatal("recovery decryption failure was accepted")
+	}
+}