From 66e86e55ea9d5f4c5252e204395d588eb19ca1b6 Mon Sep 17 00:00:00 2001
From: MichaelFisher1997 <contact@michaelfisher.tech>
Date: Sat, 25 Apr 2026 19:02:32 +0000
Subject: [PATCH] fix: require Flux image warmup before bootstrap

---
 .gitea/workflows/deploy.yml | 22 ++++++++++++++++++++++
 1 file changed, 22 insertions(+)

diff --git a/.gitea/workflows/deploy.yml b/.gitea/workflows/deploy.yml
index 3275955..35901cd 100644
--- a/.gitea/workflows/deploy.yml
+++ b/.gitea/workflows/deploy.yml
@@ -410,6 +410,27 @@ jobs:
             --from-file=identity="$HOME/.ssh/id_ed25519" \
             --from-file=known_hosts=/tmp/flux_known_hosts \
             --dry-run=client -o yaml | kubectl apply -f -
+          PRIMARY_CP_IP=$(python3 -c 'import json; print(json.load(open("outputs/terraform_outputs.json"))["primary_control_plane_ip"]["value"])')
+          for image in \
+            ghcr.io/fluxcd/source-controller:v1.8.0 \
+            ghcr.io/fluxcd/kustomize-controller:v1.8.1 \
+            ghcr.io/fluxcd/helm-controller:v1.5.1 \
+            ghcr.io/fluxcd/notification-controller:v1.8.1; do
+            pulled=false
+            for attempt in $(seq 1 12); do
+              echo "Pre-pulling ${image} on ${PRIMARY_CP_IP} (${attempt}/12)"
+              if ssh -i "$HOME/.ssh/id_ed25519" -o StrictHostKeyChecking=no -o ConnectTimeout=10 "ubuntu@${PRIMARY_CP_IP}" \
+                "sudo k3s ctr images pull '${image}'"; then
+                pulled=true
+                break
+              fi
+              sleep 20
+            done
+            if [ "${pulled}" != "true" ]; then
+              echo "Failed to pre-pull required Flux image ${image} on ${PRIMARY_CP_IP}" >&2
+              exit 1
+            fi
+          done
           # Apply CRDs and controllers first
           kubectl apply -f clusters/prod/flux-system/gotk-components.yaml
           # Wait for CRDs to be established
@@ -424,6 +445,7 @@ jobs:
           kubectl -n flux-system patch deployment kustomize-controller --type='merge' -p="$PATCH"
           kubectl -n flux-system patch deployment helm-controller --type='merge' -p="$PATCH"
           kubectl -n flux-system patch deployment notification-controller --type='merge' -p="$PATCH"
+          kubectl -n flux-system delete pod --field-selector=status.phase!=Running || true
           flux_rollout_status source-controller
           flux_rollout_status kustomize-controller
           flux_rollout_status helm-controller