From c16b70090fac6aa906fc281095f56ac6d7cfdcd4 Mon Sep 17 00:00:00 2001
From: Thomas Hallock <thomas@evolutioniq.com>
Date: Wed, 21 Jan 2026 11:33:49 -0600
Subject: [PATCH] feat(infra): add full k8s stack mirroring docker-compose
 setup
MIME-Version: 1.0
Content-Type: text/plain; charset=UTF-8
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Terraform now deploys a complete k8s environment:
- cert-manager with Let's Encrypt (staging + prod issuers)
- Redis deployment with persistent storage
- App deployment (2 replicas, rolling updates)
- Traefik ingress with SSL, HSTS, HTTP→HTTPS redirect

Ready for switchover by forwarding ports 80/443 to k3s VM.

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>
---
 infra/terraform/.terraform.lock.hcl      |  20 ++
 infra/terraform/app.tf                   | 260 +++++++++++++++++++++++
 infra/terraform/cert-manager.tf          |  73 +++++++
 infra/terraform/main.tf                  |  20 --
 infra/terraform/outputs.tf               |  47 +++-
 infra/terraform/redis.tf                 | 120 +++++++++++
 infra/terraform/terraform.tfvars.example |  10 +
 infra/terraform/variables.tf             |  29 +++
 infra/terraform/versions.tf              |   4 +
 9 files changed, 559 insertions(+), 24 deletions(-)
 create mode 100644 infra/terraform/app.tf
 create mode 100644 infra/terraform/cert-manager.tf
 create mode 100644 infra/terraform/redis.tf
 create mode 100644 infra/terraform/terraform.tfvars.example

diff --git a/infra/terraform/.terraform.lock.hcl b/infra/terraform/.terraform.lock.hcl
index 9862dbee..ce7c176c 100644
--- a/infra/terraform/.terraform.lock.hcl
+++ b/infra/terraform/.terraform.lock.hcl
@@ -40,3 +40,23 @@ provider "registry.terraform.io/hashicorp/kubernetes" {
     "zh:faf23e45f0090eef8ba28a8aac7ec5d4fdf11a36c40a8d286304567d71c1e7db",
   ]
 }
+
+provider "registry.terraform.io/hashicorp/null" {
+  version     = "3.2.4"
+  constraints = "~> 3.2"
+  hashes = [
+    "h1:L5V05xwp/Gto1leRryuesxjMfgZwjb7oool4WS1UEFQ=",
+    "zh:59f6b52ab4ff35739647f9509ee6d93d7c032985d9f8c6237d1f8a59471bbbe2",
+    "zh:78d5eefdd9e494defcb3c68d282b8f96630502cac21d1ea161f53cfe9bb483b3",
+    "zh:795c897119ff082133150121d39ff26cb5f89a730a2c8c26f3a9c1abf81a9c43",
+    "zh:7b9c7b16f118fbc2b05a983817b8ce2f86df125857966ad356353baf4bff5c0a",
+    "zh:85e33ab43e0e1726e5f97a874b8e24820b6565ff8076523cc2922ba671492991",
+    "zh:9d32ac3619cfc93eb3c4f423492a8e0f79db05fec58e449dee9b2d5873d5f69f",
+    "zh:9e15c3c9dd8e0d1e3731841d44c34571b6c97f5b95e8296a45318b94e5287a6e",
+    "zh:b4c2ab35d1b7696c30b64bf2c0f3a62329107bd1a9121ce70683dec58af19615",
+    "zh:c43723e8cc65bcdf5e0c92581dcbbdcbdcf18b8d2037406a5f2033b1e22de442",
+    "zh:ceb5495d9c31bfb299d246ab333f08c7fb0d67a4f82681fbf47f2a21c3e11ab5",
+    "zh:e171026b3659305c558d9804062762d168f50ba02b88b231d20ec99578a6233f",
+    "zh:ed0fe2acdb61330b01841fa790be00ec6beaac91d41f311fb8254f74eb6a711f",
+  ]
+}
diff --git a/infra/terraform/app.tf b/infra/terraform/app.tf
new file mode 100644
index 00000000..8b518a40
--- /dev/null
+++ b/infra/terraform/app.tf
@@ -0,0 +1,260 @@
+# Main application deployment
+
+resource "kubernetes_secret" "app_env" {
+  metadata {
+    name      = "app-env"
+    namespace = kubernetes_namespace.abaci.metadata[0].name
+  }
+
+  data = {
+    # Add sensitive env vars here
+    # DATABASE_URL = var.database_url
+  }
+}
+
+resource "kubernetes_config_map" "app_config" {
+  metadata {
+    name      = "app-config"
+    namespace = kubernetes_namespace.abaci.metadata[0].name
+  }
+
+  data = {
+    NODE_ENV               = "production"
+    PORT                   = "3000"
+    HOSTNAME               = "0.0.0.0"
+    NEXT_TELEMETRY_DISABLED = "1"
+    REDIS_URL              = "redis://redis:6379"
+  }
+}
+
+resource "kubernetes_deployment" "app" {
+  metadata {
+    name      = "abaci-app"
+    namespace = kubernetes_namespace.abaci.metadata[0].name
+    labels = {
+      app = "abaci-app"
+    }
+  }
+
+  spec {
+    replicas = var.app_replicas
+
+    selector {
+      match_labels = {
+        app = "abaci-app"
+      }
+    }
+
+    strategy {
+      type = "RollingUpdate"
+      rolling_update {
+        max_surge       = 1
+        max_unavailable = 0
+      }
+    }
+
+    template {
+      metadata {
+        labels = {
+          app = "abaci-app"
+        }
+      }
+
+      spec {
+        container {
+          name  = "app"
+          image = var.app_image
+
+          port {
+            container_port = 3000
+          }
+
+          env_from {
+            config_map_ref {
+              name = kubernetes_config_map.app_config.metadata[0].name
+            }
+          }
+
+          env_from {
+            secret_ref {
+              name = kubernetes_secret.app_env.metadata[0].name
+            }
+          }
+
+          resources {
+            requests = {
+              memory = "256Mi"
+              cpu    = "100m"
+            }
+            limits = {
+              memory = "512Mi"
+              cpu    = "1000m"
+            }
+          }
+
+          liveness_probe {
+            http_get {
+              path = "/api/health"
+              port = 3000
+            }
+            initial_delay_seconds = 30
+            period_seconds        = 10
+            timeout_seconds       = 5
+            failure_threshold     = 3
+          }
+
+          readiness_probe {
+            http_get {
+              path = "/api/health"
+              port = 3000
+            }
+            initial_delay_seconds = 5
+            period_seconds        = 5
+            timeout_seconds       = 3
+            failure_threshold     = 3
+          }
+        }
+      }
+    }
+  }
+
+  depends_on = [kubernetes_deployment.redis]
+}
+
+resource "kubernetes_service" "app" {
+  metadata {
+    name      = "abaci-app"
+    namespace = kubernetes_namespace.abaci.metadata[0].name
+  }
+
+  spec {
+    selector = {
+      app = "abaci-app"
+    }
+
+    port {
+      port        = 80
+      target_port = 3000
+    }
+
+    type = "ClusterIP"
+  }
+}
+
+# Ingress with SSL via cert-manager
+resource "kubernetes_ingress_v1" "app" {
+  metadata {
+    name      = "abaci-app"
+    namespace = kubernetes_namespace.abaci.metadata[0].name
+    annotations = {
+      "cert-manager.io/cluster-issuer"           = var.use_staging_certs ? "letsencrypt-staging" : "letsencrypt-prod"
+      "traefik.ingress.kubernetes.io/router.entrypoints" = "websecure"
+      # HSTS headers
+      "traefik.ingress.kubernetes.io/router.middlewares" = "${kubernetes_namespace.abaci.metadata[0].name}-hsts@kubernetescrd"
+    }
+  }
+
+  spec {
+    ingress_class_name = "traefik"
+
+    tls {
+      hosts       = [var.app_domain]
+      secret_name = "abaci-tls"
+    }
+
+    rule {
+      host = var.app_domain
+
+      http {
+        path {
+          path      = "/"
+          path_type = "Prefix"
+
+          backend {
+            service {
+              name = kubernetes_service.app.metadata[0].name
+              port {
+                number = 80
+              }
+            }
+          }
+        }
+      }
+    }
+  }
+
+  depends_on = [null_resource.cert_manager_issuers]
+}
+
+# HSTS middleware
+resource "kubernetes_manifest" "hsts_middleware" {
+  manifest = {
+    apiVersion = "traefik.io/v1alpha1"
+    kind       = "Middleware"
+    metadata = {
+      name      = "hsts"
+      namespace = kubernetes_namespace.abaci.metadata[0].name
+    }
+    spec = {
+      headers = {
+        stsSeconds           = 63072000
+        stsIncludeSubdomains = true
+        stsPreload           = true
+      }
+    }
+  }
+}
+
+# HTTP to HTTPS redirect
+resource "kubernetes_ingress_v1" "app_http_redirect" {
+  metadata {
+    name      = "abaci-app-http-redirect"
+    namespace = kubernetes_namespace.abaci.metadata[0].name
+    annotations = {
+      "traefik.ingress.kubernetes.io/router.entrypoints"  = "web"
+      "traefik.ingress.kubernetes.io/router.middlewares"  = "${kubernetes_namespace.abaci.metadata[0].name}-redirect-https@kubernetescrd"
+    }
+  }
+
+  spec {
+    ingress_class_name = "traefik"
+
+    rule {
+      host = var.app_domain
+
+      http {
+        path {
+          path      = "/"
+          path_type = "Prefix"
+
+          backend {
+            service {
+              name = kubernetes_service.app.metadata[0].name
+              port {
+                number = 80
+              }
+            }
+          }
+        }
+      }
+    }
+  }
+}
+
+# Redirect middleware
+resource "kubernetes_manifest" "redirect_https_middleware" {
+  manifest = {
+    apiVersion = "traefik.io/v1alpha1"
+    kind       = "Middleware"
+    metadata = {
+      name      = "redirect-https"
+      namespace = kubernetes_namespace.abaci.metadata[0].name
+    }
+    spec = {
+      redirectScheme = {
+        scheme    = "https"
+        permanent = true
+      }
+    }
+  }
+}
diff --git a/infra/terraform/cert-manager.tf b/infra/terraform/cert-manager.tf
new file mode 100644
index 00000000..e72c2cd1
--- /dev/null
+++ b/infra/terraform/cert-manager.tf
@@ -0,0 +1,73 @@
+# cert-manager for automatic Let's Encrypt SSL certificates
+
+resource "helm_release" "cert_manager" {
+  name             = "cert-manager"
+  repository       = "https://charts.jetstack.io"
+  chart            = "cert-manager"
+  namespace        = "cert-manager"
+  create_namespace = true
+  version          = "v1.14.4"
+
+  set {
+    name  = "installCRDs"
+    value = "true"
+  }
+
+  set {
+    name  = "global.leaderElection.namespace"
+    value = "cert-manager"
+  }
+}
+
+# ClusterIssuers need to be applied after cert-manager CRDs are installed
+# Using local-exec since kubernetes_manifest validates CRDs at plan time
+
+resource "null_resource" "cert_manager_issuers" {
+  depends_on = [helm_release.cert_manager]
+
+  provisioner "local-exec" {
+    command = <<-EOT
+      export KUBECONFIG=${pathexpand(var.kubeconfig_path)}
+
+      # Wait for cert-manager webhook to be ready
+      kubectl wait --for=condition=Available deployment/cert-manager-webhook -n cert-manager --timeout=120s
+
+      # Apply ClusterIssuers
+      cat <<EOF | kubectl apply -f -
+      apiVersion: cert-manager.io/v1
+      kind: ClusterIssuer
+      metadata:
+        name: letsencrypt-prod
+      spec:
+        acme:
+          server: https://acme-v02.api.letsencrypt.org/directory
+          email: ${var.letsencrypt_email}
+          privateKeySecretRef:
+            name: letsencrypt-prod-key
+          solvers:
+          - http01:
+              ingress:
+                class: traefik
+      ---
+      apiVersion: cert-manager.io/v1
+      kind: ClusterIssuer
+      metadata:
+        name: letsencrypt-staging
+      spec:
+        acme:
+          server: https://acme-staging-v02.api.letsencrypt.org/directory
+          email: ${var.letsencrypt_email}
+          privateKeySecretRef:
+            name: letsencrypt-staging-key
+          solvers:
+          - http01:
+              ingress:
+                class: traefik
+      EOF
+    EOT
+  }
+
+  triggers = {
+    email = var.letsencrypt_email
+  }
+}
diff --git a/infra/terraform/main.tf b/infra/terraform/main.tf
index f0a7aca9..941220c7 100644
--- a/infra/terraform/main.tf
+++ b/infra/terraform/main.tf
@@ -18,23 +18,3 @@ resource "kubernetes_namespace" "abaci" {
     }
   }
 }
-
-# Example: Redis deployment (optional - can use this instead of Docker Redis)
-# Uncomment when ready to migrate Redis to k3s
-#
-# resource "helm_release" "redis" {
-#   name       = "redis"
-#   repository = "https://charts.bitnami.com/bitnami"
-#   chart      = "redis"
-#   namespace  = kubernetes_namespace.abaci.metadata[0].name
-#
-#   set {
-#     name  = "architecture"
-#     value = "standalone"
-#   }
-#
-#   set {
-#     name  = "auth.enabled"
-#     value = "false"
-#   }
-# }
diff --git a/infra/terraform/outputs.tf b/infra/terraform/outputs.tf
index ff265c33..0a312727 100644
--- a/infra/terraform/outputs.tf
+++ b/infra/terraform/outputs.tf
@@ -3,10 +3,49 @@ output "namespace" {
   value       = kubernetes_namespace.abaci.metadata[0].name
 }
 
-output "cluster_info" {
-  description = "k3s cluster information"
+output "app_service" {
+  description = "App service details"
   value = {
-    kubeconfig = var.kubeconfig_path
-    namespace  = var.namespace
+    name      = kubernetes_service.app.metadata[0].name
+    namespace = kubernetes_service.app.metadata[0].namespace
+    port      = 80
   }
 }
+
+output "redis_service" {
+  description = "Redis service details"
+  value = {
+    name      = kubernetes_service.redis.metadata[0].name
+    namespace = kubernetes_service.redis.metadata[0].namespace
+    url       = "redis://redis.${kubernetes_namespace.abaci.metadata[0].name}.svc.cluster.local:6379"
+  }
+}
+
+output "ingress_info" {
+  description = "Ingress information"
+  value = {
+    domain     = var.app_domain
+    tls_secret = "abaci-tls"
+  }
+}
+
+output "switchover_checklist" {
+  description = "Steps to switch traffic from Docker to k8s"
+  value       = <<-EOT
+    To switch traffic from Docker Compose to k8s:
+
+    1. Ensure k8s pods are healthy:
+       kubectl get pods -n abaci
+
+    2. Update port forwarding on router:
+       - Forward ports 80 and 443 to k3s-node VM (192.168.86.37)
+       - Or update DNS to point to VM's public IP
+
+    3. Verify SSL certificate is issued:
+       kubectl get certificate -n abaci
+
+    4. Test the site via k8s
+
+    5. To rollback: revert port forwarding to NAS
+  EOT
+}
diff --git a/infra/terraform/redis.tf b/infra/terraform/redis.tf
new file mode 100644
index 00000000..f771cff5
--- /dev/null
+++ b/infra/terraform/redis.tf
@@ -0,0 +1,120 @@
+# Redis deployment for session storage and Socket.IO
+
+resource "kubernetes_deployment" "redis" {
+  metadata {
+    name      = "redis"
+    namespace = kubernetes_namespace.abaci.metadata[0].name
+    labels = {
+      app = "redis"
+    }
+  }
+
+  spec {
+    replicas = 1
+
+    selector {
+      match_labels = {
+        app = "redis"
+      }
+    }
+
+    template {
+      metadata {
+        labels = {
+          app = "redis"
+        }
+      }
+
+      spec {
+        container {
+          name  = "redis"
+          image = "redis:7-alpine"
+
+          args = ["redis-server", "--appendonly", "yes"]
+
+          port {
+            container_port = 6379
+          }
+
+          resources {
+            requests = {
+              memory = "128Mi"
+              cpu    = "100m"
+            }
+            limits = {
+              memory = "256Mi"
+              cpu    = "500m"
+            }
+          }
+
+          volume_mount {
+            name       = "redis-data"
+            mount_path = "/data"
+          }
+
+          liveness_probe {
+            exec {
+              command = ["redis-cli", "ping"]
+            }
+            initial_delay_seconds = 5
+            period_seconds        = 10
+          }
+
+          readiness_probe {
+            exec {
+              command = ["redis-cli", "ping"]
+            }
+            initial_delay_seconds = 5
+            period_seconds        = 5
+          }
+        }
+
+        volume {
+          name = "redis-data"
+          persistent_volume_claim {
+            claim_name = kubernetes_persistent_volume_claim.redis_data.metadata[0].name
+          }
+        }
+      }
+    }
+  }
+}
+
+resource "kubernetes_persistent_volume_claim" "redis_data" {
+  metadata {
+    name      = "redis-data"
+    namespace = kubernetes_namespace.abaci.metadata[0].name
+  }
+
+  spec {
+    access_modes = ["ReadWriteOnce"]
+    resources {
+      requests = {
+        storage = "1Gi"
+      }
+    }
+    storage_class_name = "local-path" # k3s default storage class
+  }
+
+  wait_until_bound = false # local-path uses WaitForFirstConsumer
+}
+
+resource "kubernetes_service" "redis" {
+  metadata {
+    name      = "redis"
+    namespace = kubernetes_namespace.abaci.metadata[0].name
+  }
+
+  spec {
+    selector = {
+      app = "redis"
+    }
+
+    port {
+      port        = 6379
+      target_port = 6379
+    }
+
+    type = "ClusterIP"
+  }
+}
diff --git a/infra/terraform/terraform.tfvars.example b/infra/terraform/terraform.tfvars.example
new file mode 100644
index 00000000..d308bf64
--- /dev/null
+++ b/infra/terraform/terraform.tfvars.example
@@ -0,0 +1,10 @@
+# Copy this to terraform.tfvars and fill in values
+
+# Required
+letsencrypt_email = "your-email@example.com"
+
+# Optional overrides
+# app_domain        = "abaci.one"
+# app_image         = "ghcr.io/antialias/soroban-abacus-flashcards:latest"
+# app_replicas      = 2
+# use_staging_certs = true  # Set to true when testing to avoid rate limits
diff --git a/infra/terraform/variables.tf b/infra/terraform/variables.tf
index 7258ab75..c2576b74 100644
--- a/infra/terraform/variables.tf
+++ b/infra/terraform/variables.tf
@@ -9,3 +9,32 @@ variable "namespace" {
   type        = string
   default     = "abaci"
 }
+
+variable "app_domain" {
+  description = "Domain name for the application"
+  type        = string
+  default     = "abaci.one"
+}
+
+variable "app_image" {
+  description = "Docker image for the application"
+  type        = string
+  default     = "ghcr.io/antialias/soroban-abacus-flashcards:latest"
+}
+
+variable "app_replicas" {
+  description = "Number of app replicas"
+  type        = number
+  default     = 2
+}
+
+variable "letsencrypt_email" {
+  description = "Email for Let's Encrypt certificate notifications"
+  type        = string
+}
+
+variable "use_staging_certs" {
+  description = "Use Let's Encrypt staging (for testing, avoids rate limits)"
+  type        = bool
+  default     = false
+}
diff --git a/infra/terraform/versions.tf b/infra/terraform/versions.tf
index fc5d0059..3c82f90a 100644
--- a/infra/terraform/versions.tf
+++ b/infra/terraform/versions.tf
@@ -10,5 +10,9 @@ terraform {
       source  = "hashicorp/helm"
       version = "~> 2.12"
     }
+    null = {
+      source  = "hashicorp/null"
+      version = "~> 3.2"
+    }
   }
 }