k8s Cluster Operations — joelclaw on Talos

Architecture

Mac Mini (localhost ports)
  └─ Lima SSH mux (~/.colima/_lima/colima/ssh.sock) ← NEVER KILL
      └─ Colima VM (8 CPU, 16 GiB, 100 GiB, VZ framework, aarch64)
          └─ Docker 29.x + buildx (joelclaw-builder, docker-container driver)
              └─ Talos v1.12.4 container (joelclaw-controlplane-1)
                  └─ k8s v1.35.0 (single node, Flannel CNI)
                      └─ joelclaw namespace (privileged PSA)

⚠️ Talos has NO shell. No bash, no /bin/sh, nothing. You cannot docker exec into the Talos container. Use talosctl for node operations and the Colima VM (ssh lima-colima) for host-level operations like modprobe.

Colima Stability Rules (2026-03-17 incident)

Setting	Value	Reason
CPU	8	Match k8s workload requests (~2.8 CPU, 72%)
Memory	16 GiB	32GB causes macOS memory pressure → VM kill
nestedVirtualization	OFF by default	Crashes VM under load (image builds, heavy scheduling). Toggle ON only for Firecracker testing
vmType	vz	Required for Apple Silicon
mountType	virtiofs	Fastest option with VZ

nestedVirtualization: true is unstable on M4 Pro under load. It causes the Colima VM to silently crash during Docker builds/pushes. Each crash:

• Kills the Talos container mid-operation
• Corrupts Redis AOF (if caught mid-write) → crash-loop on restart
• Breaks Lima socket forwarding → docker CLI on macOS disconnects
• Creates stale k8s pods that re-pull images → amplifies pressure

Recovery from Colima crash-loop:

1. colima stop && colima start — basic restart
2. If Redis crash-loops: redis-check-aof --fix (see Redis AOF Recovery below)
3. If Restate has stuck invocations: purge PVC or kill via admin API
4. If native Docker socket dead: use SSH tunnel ssh -L /tmp/docker.sock:/var/run/docker.sock

Docker image builds should use the buildx container builder (docker buildx build --builder joelclaw-builder) to isolate build IO from k8s workloads.

Redis AOF Recovery

If Redis crash-loops after a VM restart with Bad file format reading the append only file:

# 1. Scale down Redis (or use a temp pod if StatefulSet can't mount PVC concurrently)
kubectl -n joelclaw apply -f - <<'EOF'
apiVersion: v1
kind: Pod
metadata:
  name: redis-fix
  namespace: joelclaw
spec:
  tolerations:
    - key: node-role.kubernetes.io/control-plane
      operator: Exists
      effect: NoSchedule
  containers:
    - name: fix
      image: redis:7-alpine
      command: ["sh", "-c", "cd /data/appendonlydir && echo y | redis-check-aof --fix *.incr.aof && redis-check-aof *.incr.aof"]
      volumeMounts:
        - name: data
          mountPath: /data
  restartPolicy: Never
  volumes:
    - name: data
      persistentVolumeClaim:
        claimName: data-redis-0
EOF
# 2. Wait, check logs, then clean up
kubectl -n joelclaw logs redis-fix
kubectl -n joelclaw delete pod redis-fix --force
# 3. Restart Redis
kubectl -n joelclaw delete pod redis-0

For port mappings, recovery procedures, and cluster recreation steps, read references/operations.md.

Reboot-heal persistence rule (2026-04-15 incident)

infra/k8s-reboot-heal.sh runs under launchd as a fresh process every interval. Any recovery marker that only lives in shell memory dies at the end of that tick.

That means flannel/event-healing state must be persisted on disk. Canonical path:

~/.local/state/k8s-reboot-heal.env

Persist at least:

• COLIMA_START_EPOCH
• RECOVERY_START_EPOCH
• LAST_FLANNEL_RESTART_EPOCH
• COLIMA_UNHEALTHY_STREAK
• LAST_COLIMA_UNHEALTHY_EPOCH
• LAST_COLIMA_FORCE_CYCLE_EPOCH
• LAST_COLIMA_FAILED_RECOVERY_EPOCH

Why this matters: kubelet FailedCreatePodSandBox events mentioning missing subnet.env can stay recent for minutes after the first repair. If the healer forgets that it already restarted flannel, the next launchd tick can bounce flannel again and knock healthy services like Typesense back into 503 warmup for no good reason. The extra failed-recovery marker also stops the system from counting a one-minute green flash as success and then force-cycling Colima again when the control path collapses.

Kubeconfig Port Drift (2026-03-21 incident)

Docker port mappings for k8s API (6443) and Talos API (50000) are not pinned — they use random host ports assigned at container creation. All service ports (3111, 8288, 6379, etc.) ARE pinned 1:1.

When the Colima VM or Talos container restarts, Docker may reassign different random ports for 6443/50000. Kubeconfig goes stale, kubectl fails, and everything that depends on it (joelclaw CLI, health checks, pod inspection) breaks silently.

Symptoms: kubectl returns tls: internal error or connection refused. All pods are actually running — only the kubeconfig routing is wrong.

Fix:

# 1. Regenerate kubeconfig from talosctl (which has the correct port)
talosctl --talosconfig ~/.talos/config --nodes 127.0.0.1 kubeconfig --force

# 2. Switch to the new context
kubectl config use-context "$(kubectl config get-contexts -o name | grep joelclaw | head -1)"

# 3. Clean stale contexts (optional)
kubectl config delete-context admin@joelclaw  # if stale entry exists

Self-heal: health.sh now auto-detects and fixes this before running checks.

Root cause: Container was created without pinning these ports. To permanently fix, recreate the container with explicit port bindings for 6443:6443 and 50000:50000. This requires cluster recreation — a bigger operation.

Durable recovery rule (ADR-0244)

A Colima restart is not recovery.

After any colima start / force-cycle, the system only counts recovery as real if a post-restart stability window stays healthy across repeated passes for:

• Colima SSH
• Docker socket
• Kubernetes API
• Typesense localhost health
• Inngest localhost health

If those regress during the verification window, classify the event as a failed recovery, capture proof artifacts, and stop repeated force-cycles for the configured hold period. The point is durability, not healer theatre.

Quick Health Check

kubectl get pods -n joelclaw                          # all pods
curl -s localhost:3111/api/inngest                     # system-bus-worker → 200
curl -s localhost:7880/                                # LiveKit → "OK"
curl -s localhost:8108/health                          # Typesense → {"ok":true}
curl -s localhost:8288/health                          # Inngest → {"status":200}
curl -s localhost:9070/deployments                     # Restate admin → deployments list
curl -s localhost:9627/xrpc/_health                    # PDS → {"version":"..."}
kubectl exec -n joelclaw redis-0 -- redis-cli ping     # → PONG
joelclaw restate cron status                           # Dkron scheduler → healthy via temporary CLI tunnel

Services

Service	Type	Pod	Ports (Mac→NodePort)	Helm?
Redis	StatefulSet	redis-0	6379→6379	No
Typesense	StatefulSet	typesense-0	8108→8108	No
Inngest	StatefulSet	inngest-0	8288→8288, 8289→8289	No
Restate	StatefulSet	restate-0	8080→8080, 9070→9070, 9071→9071	No
system-bus-worker	Deployment	system-bus-worker-*	3111→3111	No
restate-worker	Deployment	restate-worker-*	in-cluster only (restate-worker:9080)	No
docs-api	Deployment	docs-api-*	3838→3838	No
LiveKit	Deployment	livekit-server-*	7880→7880, 7881→7881	Yes (livekit/livekit-server 1.9.0)
PDS	Deployment	bluesky-pds-*	9627→3000	Yes (nerkho/bluesky-pds 0.4.2)
MinIO	StatefulSet	minio-0	30900→30900, 30901→30901	No
Dkron	StatefulSet	dkron-0	in-cluster only (dkron-svc:8080)	No
AIStor Operator (aistor ns)	Deployments	adminjob-operator, object-store-operator	n/a	Yes (minio/aistor-operator)
AIStor ObjectStore (aistor ns)	StatefulSet	aistor-s3-pool-0-0	31000 (S3 TLS), 31001 (console)	Yes (minio/aistor-objectstore)

Restate / Firecracker runtime notes

• deployment/restate-worker is intentionally privileged and mounts /dev/kvm (hostPath type "" — optional).
• PVC firecracker-images at /tmp/firecracker-test stores kernel, rootfs, and snapshot artifacts.
• When nestedVirtualization is OFF: /dev/kvm absent, microvm DAG handler fails, but shell/infer/noop handlers work normally.
• When nestedVirtualization is ON: Firecracker one-shot exec works (create workspace ext4 → write command → boot VM → guest executes → poweroff → read results).
• Restate retry caps: dagWorker maxAttempts=5, dagOrchestrator maxAttempts=3. Prevents journal poisoning.
• Restate journal purge (if stuck invocations block work): scale down Restate, mount PVC with temp pod, rm -rf /restate-data/*, scale back up, re-register worker.
• Re-register worker: curl -X POST http://localhost:9070/deployments -H 'content-type: application/json' -d '{"uri":"http://restate-worker:9080"}'

⚠️ PDS port trap: Docker maps 9627→3000 (host→container). NodePort must be 3000 to match the container-side port. If set to 9627, traffic won't route.

Rule: NodePort value = Docker's container-side port, not host-side.

Agent Runner (Cold k8s Jobs)

Status: local sandbox remains the default/live path; the k8s backend is now code-landed and opt-in, but still needs supervised rollout before calling it earned runtime.

The agent runner executes sandboxed story runs as isolated k8s Jobs. Jobs are created dynamically via @joelclaw/agent-execution/job-spec — no static manifests.

Runtime Image Contract

See k8s/agent-runner.yaml for the full specification.

Required components:

• Git (checkout, diff, commit)
• Bun runtime
• runner-installed agent tooling (currently claude and/or other installed CLIs)
• /workspace working directory
• runtime entrypoint at /app/packages/agent-execution/src/job-runner.ts

Configuration via environment variables:

• Request metadata: WORKFLOW_ID, REQUEST_ID, STORY_ID, SANDBOX_PROFILE, BASE_SHA, EXECUTION_BACKEND, JOB_NAME, JOB_NAMESPACE
• Repo materialization: REPO_URL, REPO_BRANCH, optional HOST_REQUESTED_CWD
• Agent identity: AGENT_NAME, AGENT_MODEL, AGENT_VARIANT, AGENT_PROGRAM
• Execution config: SESSION_ID, TIMEOUT_SECONDS
• Task prompt: TASK_PROMPT_B64 (base64-encoded)
• Verification: VERIFICATION_COMMANDS_B64 (base64-encoded JSON array)
• Callback path: RESULT_CALLBACK_URL, RESULT_CALLBACK_TOKEN

Expected behavior:

1. Decode task from TASK_PROMPT_B64
2. Materialize repo from REPO_URL / REPO_BRANCH at BASE_SHA
3. Execute the requested AGENT_PROGRAM
4. Run verification commands (if set)
5. Print SandboxExecutionResult markers to stdout and POST the same result to /internal/agent-result
6. Exit 0 (success) or non-zero (failure)

Current truthful limit:

• pi remains local-backend only for now; do not pretend the pod runner can execute pi story runs yet.

Job Lifecycle

import { generateJobSpec, generateJobDeletion } from "@joelclaw/agent-execution";

// 1. Generate Job spec
const spec = generateJobSpec(request, {
  runtime: {
    image: "ghcr.io/joelhooks/agent-runner:latest",
    imagePullPolicy: "Always",
    command: ["bun", "run", "/app/packages/agent-execution/src/job-runner.ts"],
  },
  namespace: "joelclaw",
  imagePullSecret: "ghcr-pull",
  resultCallbackUrl: "http://host.docker.internal:3111/internal/agent-result",
  resultCallbackToken: process.env.OTEL_EMIT_TOKEN,
});

// 2. Apply to cluster (via kubectl or k8s client library)
// 3. Job runs → Pod materializes repo, executes agent, posts SandboxExecutionResult callback
// 4. Host worker can recover the same terminal result from log markers if callback delivery fails
// 5. Job auto-deletes after TTL (default: 5 minutes)

// Cancel a running Job
const deletion = generateJobDeletion("req-xyz");
// kubectl delete job ${deletion.name} -n ${deletion.namespace}

Resource Defaults

• CPU: 500m request, 2 limit
• Memory: 1Gi request, 4Gi limit
• Active deadline: 1 hour
• TTL after completion: 5 minutes
• Backoff limit: 0 (no retries)

Security

• Non-root execution (UID 1000, GID 1000)
• No privilege escalation
• All capabilities dropped
• RuntimeDefault seccomp profile
• Control plane toleration for single-node cluster

Verification Commands

# List agent runner Jobs
kubectl get jobs -n joelclaw -l app.kubernetes.io/name=agent-runner

# Check Job status
kubectl describe job <job-name> -n joelclaw

# View logs
kubectl logs job/<job-name> -n joelclaw

# Check for stale Jobs (should be auto-deleted by TTL)
kubectl get jobs -n joelclaw --show-all

Current State

• ✅ Job spec generator (packages/agent-execution/src/job-spec.ts)
• ✅ Runtime contract (k8s/agent-runner.yaml)
• ✅ Tests (packages/agent-execution/__tests__/job-spec.test.ts)
• ⏳ Runtime image not yet built (Story 3)
• ⏳ Hot-image CronJob not yet implemented (Story 4)
• ⏳ Warm-pool scheduler not yet implemented (Story 5)
• ⏳ Restate integration not yet wired (Story 6)

NAS NFS Access from k8s (ADR-0088 Phase 2.5)

k8s pods can mount NAS storage over NFS via a LAN route through the Colima bridge.

How it works

k8s pod → Talos container (10.5.0.x) → Docker NAT → Colima VM
  → ip route 192.168.1.0/24 via 192.168.64.1 dev col0
  → macOS host (IP forwarding enabled) → LAN → NAS (192.168.1.163)

Root cause of prior failures: VZ framework's shared networking on eth0 doesn't properly forward LAN-bound traffic. The fix routes LAN traffic through col0 (Colima bridge → macOS host) instead.

Route persistence

The LAN route is set in two places for reliability:

1. Colima provision script (~/.colima/default/colima.yaml) — runs on colima start (cold boot)
2. k8s-reboot-heal (~/Code/joelhooks/joelclaw/infra/k8s-reboot-heal.sh) — reasserts the route during reboot recovery ticks

Both execute: ip route replace 192.168.1.0/24 via 192.168.64.1 dev col0

Duplicate tunnel ownership is a bug (2026-04-16)

com.joel.colima-tunnel is deprecated. Colima/Lima already forwards the docker-published host ports for joelclaw-controlplane-1, so a second autossh daemon on those same ports is not redundancy — it's interference.

Rules:

• com.joel.colima is the only boot/start helper for the VM; it must not keep a periodic StartInterval
• com.joel.colima-tunnel should be absent from /Library/LaunchDaemons/; install-critical-launchdaemons.sh removes it instead of reinstalling it
• do not run a second autossh daemon on ports Colima/Lima already publishes for joelclaw-controlplane-1 (3838, 6379, 7880, 7881, 8108, 8288, 8289, 9627, 64784)
• do not kill generic ssh listeners on those host ports; that can kill Lima's own forwarders
• infra/colima-tunnel.sh is now only a deprecated compatibility stub so stale launchd installs exit cleanly instead of fighting Lima
• com.joel.kube-operator-access is the allowed exception because it owns dedicated operator-only loopback ports that Colima/Lima do not publish themselves: 16443 -> 10.5.0.2:6443 for kube-apiserver and 15000 -> 10.5.0.2:50000 for Talos
• the operator daemon must use ssh -F ~/.colima/_lima/colima/ssh.config -S none -o ControlPath=none -o ControlMaster=no -o ControlPersist=no; do not trust the generic Lima mux path for long-lived kubectl/talos access after a rebuild
• once the daemon is installed, kubectl should use https://127.0.0.1:16443 and talosctl should use 127.0.0.1:15000
• com.joel.k8s-reboot-heal must use the same JSON status check; a plain colima status false-negative can force-cycle the VM and retrigger the flannel/NAS failure cascade during reboot recovery
• do not trust status output alone when deciding to cycle Colima; if the Docker socket or Colima SSH path is still healthy, treat the VM as alive and keep your hands off it
• a Colima force-cycle now requires confirmed evidence; one ugly observation is not enough to panic-cycle the VM
• confirmation can come from consecutive launchd ticks or from a short rapid-confirmation window when both the Docker socket and Colima SSH path stay down long enough to prove a severe collapse
• after any Colima force-cycle, honor the persisted cooldown in ~/.local/state/k8s-reboot-heal.env so Talos and workload warmup can finish before another escalation is even considered
• if the host path is still down but escalation is not yet earned, bail out early and mark the tick failed; do not pretend downstream kube/NAS repair steps are actionable without Colima host access
• reboot recovery is not healthy until the NAS route 192.168.1.0/24 via 192.168.64.1 dev col0 exists again and NFS is reachable from the Colima VM
• flannel can be "Running" while kubelet still reports failed to load flannel 'subnet.env' file; treat recent FailedCreatePodSandBox events with that message as a restart signal for the flannel pod

Available PVs

PV	NFS Path	Capacity	Access	Use
nas-nvme	192.168.1.163:/volume2/data	1.5TB	RWX	NVMe RAID1: backups, snapshots, models, sessions
nas-hdd	192.168.1.163:/volume1/joelclaw	50TB	RWX	HDD RAID5: books, docs-artifacts, archives, otel
minio-nfs-pv	192.168.1.163:/volume1/joelclaw	1TB	RWO	HDD tier: MinIO object storage (same export)

Mounting NAS in a pod

volumes:
  - name: nas
    persistentVolumeClaim:
      claimName: nas-nvme
containers:
  - volumeMounts:
      - name: nas
        mountPath: /nas
        # Optional: subPath for specific dir
        subPath: typesense

Rules

• Always use IP (192.168.1.163), never hostname (three-body). DNS doesn't resolve from inside k8s.
• Always use nfsvers=3,tcp,resvport,noatime mount options. NFSv4 has issues with Asustor ADM.
• NAS unavailability degrades gracefully with soft mount option — returns errors, doesn't hang pods.
• NFS write performance: ~660 MiB/s over 10GbE with jumbo frames. Good for sequential I/O (backups, snapshots). Latency-sensitive workloads (Redis, active Typesense indexes) stay on local SSD.
• If NFS mount fails after Colima restart: verify the route exists: colima ssh -- ip route | grep 192.168.1.0

Verify connectivity

# From Colima VM
colima ssh -- timeout 2 bash -c "echo > /dev/tcp/192.168.1.163/2049" && echo "NFS OK"

# From k8s pod
kubectl run nfs-test --image=busybox --restart=Never -n joelclaw \
  --overrides='{"spec":{"tolerations":[{"key":"node-role.kubernetes.io/control-plane","operator":"Exists","effect":"NoSchedule"}],"containers":[{"name":"t","image":"busybox","command":["sh","-c","ls /nas && echo OK"],"volumeMounts":[{"name":"n","mountPath":"/nas"}]}],"volumes":[{"name":"n","persistentVolumeClaim":{"claimName":"nas-nvme"}}]}}'
kubectl logs nfs-test -n joelclaw && kubectl delete pod nfs-test -n joelclaw --force

Deploy Commands

# Manifests (redis, typesense, inngest, dkron)
kubectl apply -f ~/Code/joelhooks/joelclaw/k8s/

# Restate runtime
kubectl apply -f ~/Code/joelhooks/joelclaw/k8s/restate.yaml
kubectl apply -f ~/Code/joelhooks/joelclaw/k8s/firecracker-pvc.yaml
kubectl rollout status statefulset/restate -n joelclaw
~/Code/joelhooks/joelclaw/k8s/publish-restate-worker.sh
curl -fsS http://localhost:9070/deployments

# Dkron phase-1 scheduler (ClusterIP API + CLI-managed short-lived tunnel access)
kubectl apply -f ~/Code/joelhooks/joelclaw/k8s/dkron.yaml
kubectl rollout status statefulset/dkron -n joelclaw
joelclaw restate cron status
joelclaw restate cron sync-tier1        # seed/update ADR-0216 tier-1 jobs

# system-bus worker (build + push GHCR + apply + rollout wait)
~/Code/joelhooks/joelclaw/k8s/publish-system-bus-worker.sh

# LiveKit (Helm + reconcile patches)
~/Code/joelhooks/joelclaw/k8s/reconcile-livekit.sh joelclaw

# AIStor (Helm operator + objectstore)
# Defaults to isolated `aistor` namespace to avoid service-name collisions with legacy `joelclaw/minio`.
# Cutover override (explicit only): AISTOR_OBJECTSTORE_NAMESPACE=joelclaw AISTOR_ALLOW_JOELCLAW_NAMESPACE=true
~/Code/joelhooks/joelclaw/k8s/reconcile-aistor.sh

# PDS (Helm) — always patch NodePort to 3000
# (export current values first if the release already exists)
helm get values bluesky-pds -n joelclaw > /tmp/pds-values-live.yaml 2>/dev/null || true
helm upgrade --install bluesky-pds nerkho/bluesky-pds \
  -n joelclaw -f /tmp/pds-values-live.yaml
kubectl patch svc bluesky-pds -n joelclaw --type='json' \
  -p='[{"op":"replace","path":"/spec/ports/0/nodePort","value":3000}]'

Auto Deploy (GitHub Actions)

• Workflow: .github/workflows/system-bus-worker-deploy.yml
• Trigger: push to main touching packages/system-bus/** or worker deploy files
• Behavior:
  • builds/pushes ghcr.io/joelhooks/system-bus-worker:${GITHUB_SHA} + :latest
  • runs deploy job on self-hosted runner
  • updates k8s deployment image + waits for rollout + probes worker health
• If deploy job is queued forever, check that a self-hosted runner is online on the Mac Mini.

GHCR push 403 Forbidden

Cause: GITHUB_TOKEN (default Actions token) does not have packages:write scope for this repo. A dedicated PAT is required.

Fix already applied: Workflow uses secrets.GHCR_PAT (not secrets.GITHUB_TOKEN) for the GHCR login step. The PAT is stored in:

• GitHub repo secrets as GHCR_PAT (set via GitHub UI)
• agent-secrets as ghcr_pat (secrets lease ghcr_pat)

If this breaks again: PAT may have expired. Regenerate at github.com → Settings → Developer settings → PATs, update both stores.

Local fallback (bypass GHA entirely):

DOCKER_CONFIG_DIR=$(mktemp -d)
echo '{"credsStore":""}' > "$DOCKER_CONFIG_DIR/config.json"
export DOCKER_CONFIG="$DOCKER_CONFIG_DIR"
secrets lease ghcr_pat | docker login ghcr.io -u joelhooks --password-stdin
~/Code/joelhooks/joelclaw/k8s/publish-system-bus-worker.sh

Note: publish-system-bus-worker.sh uses gh auth token internally — if gh auth is stale, use the Docker login above before running the script, or patch it to use secrets lease ghcr_pat directly.

Resilience Rules (ADR-0148)

1. NEVER use kubectl port-forward for persistent service exposure. All long-lived operator surfaces MUST use NodePort + Docker port mappings. The narrow exception is a CLI-managed, short-lived tunnel for an otherwise in-cluster-only control surface (for example joelclaw restate cron * tunneling to dkron-svc). Port-forwards silently die on idle/restart/pod changes, so do not leave them running.
2. All workloads MUST have liveness + readiness + startup probes. Missing probes = silent hangs that never recover.
3. After any Docker/Colima/node restart: remove control-plane taint, uncordon node, verify flannel, check all pods reach Running.
4. PVC reclaimPolicy is Delete — deleting a PVC = permanent data loss. Never delete PVCs without backup.
5. firecracker-images is stateful runtime data. Treat it like a real runtime PVC: kernel, rootfs, and snapshot loss will break the microVM path.
6. Colima VM disk is limited (19GB). Monitor with colima ssh -- df -h /. Alert at >80%.
7. All launchd plists MUST set PATH including /opt/homebrew/bin. Colima shells to limactl, kubectl/talosctl live in homebrew. launchd's default PATH is /usr/bin:/bin:/usr/sbin:/sbin — no homebrew. The canonical PATH for infra plists is: /opt/homebrew/bin:/Users/joel/.local/bin:/usr/local/bin:/usr/bin:/bin:/usr/sbin:/sbin. Discovered Feb 2026: missing PATH caused 6 days of silent recovery failures.
8. Shell scripts run by launchd MUST export PATH at the top. Even if the plist sets EnvironmentVariables, belt-and-suspenders — add export PATH="/opt/homebrew/bin:..." to the script itself.

Current Probe Gaps (fix when touching these services)

• Typesense: missing liveness probe (hangs won't be detected)
• Bluesky PDS: missing readiness and startup probes
• system-bus-worker: missing startup probe

Danger Zones

1. Stale SSH mux socket after Colima restart — When Colima restarts (disk resize, crash recovery, colima stop && start), the SSH port changes but the mux socket (~/.colima/_lima/colima/ssh.sock) caches the old connection. Symptoms: kubectl port-forward fails with "tls: internal error", kubectl get nodes may intermittently work then fail. Fix: rm -f ~/.colima/_lima/colima/ssh.sock && pkill -f "ssh.*colima", then re-establish tunnels with ssh -o ControlPath=none. Always verify SSH port with colima ssh-config | grep Port after restart.
2. Adding Docker port mappings — can be hot-added without cluster recreation via hostconfig.json edit. See references/operations.md for the procedure.
3. Inngest legacy host alias in manifests — old container-host alias may still appear in legacy configs. Worker uses connect mode, so it usually still works, but prefer explicit Talos/Colima hostnames.
4. Colima zombie state — colima status reports "Running" but docker socket / SSH tunnels are dead. All k8s ports unresponsive. colima start is a no-op. Only colima restart recovers. Detect with: ssh -F ~/.colima/_lima/colima/ssh.config lima-colima "docker info" — if that fails while colima status passes, it's a zombie. The heal script handles this automatically.
5. Talos container has NO shell — No bash, no /bin/sh. Cannot docker exec into it. Kernel modules like br_netfilter must be loaded at the Colima VM level: ssh lima-colima "sudo modprobe br_netfilter".
6. AIStor service-name collision — if AIStor objectstore is deployed in joelclaw, it can claim svc/minio and break legacy MinIO assumptions. Keep AIStor objectstore in isolated namespace (aistor) unless intentionally cutting over.
7. AIStor operator webhook SSA conflict — repeated helm upgrade can fail on MutatingWebhookConfiguration caBundle ownership conflict. Current mitigation in this cluster: set operators.object-store.webhook.enabled=false in k8s/aistor-operator-values.yaml.
8. MinIO pinned tag trap — minio/minio:RELEASE.2025-10-15T17-29-55Z is not available on Docker Hub in this environment (ErrImagePull). Legacy fallback currently relies on minio/minio:latest.
9. restate-worker privilege is intentional. Do not “harden” away /dev/kvm, privileged: true, or the unconfined seccomp profile unless you are simultaneously changing the Firecracker runtime contract.
10. Dkron service-name collision — never create a bare svc/dkron. Kubernetes injects DKRON_* env vars into pods, which collides with Dkron's own config parsing. Use dkron-peer and dkron-svc.
11. Dkron PVC permissions — upstream dkron/dkron:latest currently needs root on the local-path PVC. Non-root hardening caused permission denied under /data/raft/snapshots/permTest and CrashLoopBackOff.
12. Typesense host access must be a real service contract — after the 2026-04-19 rebuild, OTEL emit hung because host code still targeted localhost:8108 while typesense had been restored as ClusterIP only. The fix was to make k8s/typesense.yaml a NodePort service on 8108 again so host worker + CLI writes have a stable path without reviving a launchd port-forward sidecar.
13. docs-api restore also needs docs-api-env — the manifest depends on secret docs-api-env with key PDF_BRAIN_API_TOKEN. The token lives in agent-secrets as pdf_brain_api_token; recreate the k8s secret before applying k8s/docs-api.yaml on a rebuilt cluster or the Deployment will stay broken.
14. knowledge search can fail right after a rebuild even when Typesense is healthy — if system_knowledge is missing you will see 404 {"message":"Collection not found"}. The CLI now auto-heals this on first joelclaw knowledge search by recreating the collection and re-syncing ADRs + skills, but an explicit joelclaw knowledge sync is still the blunt proof command.
15. PDS rebuilds are a two-step restore, not just a Helm install — recreate bluesky-pds-secrets, reinstall the bluesky-pds Helm release, force the service nodePort back to 3000, then recreate Joel's account if the PVC was wiped. The new account returns a fresh DID, so update the pds_joel_did secret afterward or host dual-write will keep authenticating against a dead repo.
16. PDS session auth is handle-first in practice — on the rebuilt PDS, com.atproto.server.createSession succeeded against joel.pds.panda.tail7af24.ts.net but rejected the raw DID. packages/system-bus/src/lib/pds.ts now resolves the handle from pds_joel_did via describeRepo before it asks for a session, which keeps the dual-write path aligned with reality.
17. Typesense "Too many open files" masquerades as raft ERROR — during large HNSW reindexes (e.g. docs_chunks_v2 ~223k rows), Typesense exhausts its 1024 default FD limit and starts logging Fail to open /proc/self/fd: Too many open files. The pod stays Running but 503s everything, and the external symptom is identical to a raft leader-election failure. Fix: wrap the container command with ulimit -n 1048576 before exec-ing /opt/typesense-server. Canonical form lives in k8s/typesense.yaml since 2026-04-19.
18. Talos container memory cap is 4 GiB by default, not the Colima VM size — docker inspect joelclaw-controlplane-1 --format '{{.HostConfig.Memory}}' returns 4294967296 even though the Colima VM has 16 GiB. Every k8s pod inside Talos shares those 4 GiB. Under Typesense otel_events / docs_chunks_v2 load the Talos container pegs at 99.8% and typesense + kubectl tunnel both go unresponsive together. Live fix without restart: ssh -F ~/.colima/_lima/colima/ssh.config lima-colima "sudo docker update --memory=12g --memory-swap=12g joelclaw-controlplane-1". After that, bump per-pod resources.limits.memory to match the real workload (Typesense raised from 4 Gi → 8 Gi on 2026-04-20).

Key Files

Path	What
~/Code/joelhooks/joelclaw/k8s/*.yaml	Service manifests
~/Code/joelhooks/joelclaw/k8s/livekit-values.yaml	LiveKit Helm values (source controlled)
~/Code/joelhooks/joelclaw/k8s/reconcile-livekit.sh	LiveKit Helm deploy + post-upgrade reconcile
~/Code/joelhooks/joelclaw/k8s/aistor-operator-values.yaml	AIStor operator Helm values
~/Code/joelhooks/joelclaw/k8s/aistor-objectstore-values.yaml	AIStor objectstore Helm values
~/Code/joelhooks/joelclaw/k8s/reconcile-aistor.sh	AIStor deploy + upgrade reconcile script
~/Code/joelhooks/joelclaw/k8s/dkron.yaml	Dkron scheduler StatefulSet + services
~/Code/joelhooks/joelclaw/k8s/publish-system-bus-worker.sh	Build/push/deploy system-bus worker to k8s
~/Code/joelhooks/joelclaw/infra/k8s-reboot-heal.sh	Reboot auto-heal script for Colima/Talos/taint/flannel
~/Code/joelhooks/joelclaw/infra/kube-operator-access.sh	launchd-managed kubectl/talos operator tunnel on 16443/15000
~/Code/joelhooks/joelclaw/infra/launchd/com.joel.k8s-reboot-heal.plist	launchd timer for reboot auto-heal
~/Code/joelhooks/joelclaw/infra/launchd/com.joel.kube-operator-access.plist	launchd service for stable operator access
~/Code/joelhooks/joelclaw/skills/k8s/references/operations.md	Cluster operations + recovery notes
~/.talos/config	Talos client config (stable endpoint: 127.0.0.1:15000)
~/.kube/config	Kubeconfig (stable server: https://127.0.0.1:16443)
~/.colima/default/colima.yaml	Colima VM config
~/Code/joelhooks/joelclaw/infra/colima-tunnel.sh	Deprecated compatibility stub; exits cleanly so stale launchd installs stop fighting Lima
~/.local/bin/colima-tunnel	Compatibility wrapper for the deprecated tunnel stub
~/.local/caddy/Caddyfile	Caddy HTTPS proxy (Tailscale)
~/Code/joelhooks/joelclaw/k8s/nas-nvme-pv.yaml	NAS NVMe NFS PV/PVC (1.5TB)
~/Code/joelhooks/joelclaw/k8s/nas-hdd-pv.yaml	NAS HDD NFS PV/PVC (50TB)

Troubleshooting

Read references/operations.md for:

• Recovery after Colima restart
• Recovery after Mac reboot
• Flannel br_netfilter crash fix
• Full cluster recreation (nuclear option)
• Caddy/Tailscale HTTPS proxy details
• All port mapping details with explanation