feat(consul): deploy HashiCorp Consul 1.22.7 via Helm chart 1.9.7

5-replica server cluster (bootstrapExpect=5) with datacenter=au-syd1,
connect enabled, raft_multiplier=10, http=8500, grpc=8502, https=-1.
10Gi cephrbd-fast-delete PVC. Gateway API HTTPRoute on 443→consul-consul-ui:80→8500.
PDB patched from policy/v1beta1 to policy/v1 for k8s 1.25+.
ArgoCD platform ApplicationSet updated to include consul overlay path.

apps/base/consul/gateway.yaml

@@ -0,0 +1,31 @@
+---
+apiVersion: gateway.networking.k8s.io/v1
+kind: Gateway
+metadata:
+  name: consul
+  namespace: consul
+  labels:
+    app.kubernetes.io/name: consul
+    app.kubernetes.io/instance: consul
+    traefik.io/instance: internal
+  annotations:
+    cert-manager.io/cluster-issuer: vault-issuer
+    cert-manager.io/common-name: consul.k8s.syd1.au.unkin.net
+    cert-manager.io/private-key-size: "4096"
+    external-dns.alpha.kubernetes.io/hostname: consul.k8s.syd1.au.unkin.net
+    external-dns.alpha.kubernetes.io/target: 198.18.200.4
+spec:
+  gatewayClassName: traefik-internal
+  listeners:
+    - name: https
+      port: 443
+      protocol: HTTPS
+      hostname: consul.k8s.syd1.au.unkin.net
+      allowedRoutes:
+        namespaces:
+          from: Same
+      tls:
+        mode: Terminate
+        certificateRefs:
+          - kind: Secret
+            name: consul-tls

apps/base/consul/httproute.yaml

@@ -0,0 +1,23 @@
+---
+apiVersion: gateway.networking.k8s.io/v1
+kind: HTTPRoute
+metadata:
+  name: consul
+  namespace: consul
+  labels:
+    app.kubernetes.io/name: consul
+    app.kubernetes.io/instance: consul
+spec:
+  hostnames:
+    - consul.k8s.syd1.au.unkin.net
+  parentRefs:
+    - name: consul
+      sectionName: https
+  rules:
+    - backendRefs:
+        - name: consul-consul-ui
+          port: 80
+      matches:
+        - path:
+            type: PathPrefix
+            value: /

apps/base/consul/kustomization.yaml

@@ -0,0 +1,8 @@
+---
+apiVersion: kustomize.config.k8s.io/v1beta1
+kind: Kustomization
+
+resources:
+  - namespace.yaml
+  - gateway.yaml
+  - httproute.yaml

apps/base/consul/namespace.yaml

@@ -0,0 +1,5 @@
+---
+apiVersion: v1
+kind: Namespace
+metadata:
+  name: consul

apps/overlays/au-syd1/consul/kustomization.yaml

@@ -0,0 +1,23 @@
+---
+apiVersion: kustomize.config.k8s.io/v1beta1
+kind: Kustomization
+
+resources:
+  - ../../../base/consul
+
+patches:
+  - target:
+      kind: PodDisruptionBudget
+      name: consul-server
+    patch: |-
+      - op: replace
+        path: /apiVersion
+        value: policy/v1
+
+helmCharts:
+  - name: consul
+    repo: https://helm.releases.hashicorp.com
+    version: "1.9.7"
+    releaseName: consul
+    namespace: consul
+    valuesFile: values.yaml

apps/overlays/au-syd1/consul/values.yaml

@@ -0,0 +1,51 @@
+global:
+  name: consul
+  datacenter: au-syd1
+  domain: consul
+
+server:
+  image: hashicorp/consul:1.22.7
+  replicas: 5
+  bootstrapExpect: 5
+  storage: 10Gi
+  storageClass: cephrbd-fast-delete
+
+  connect: true
+
+  extraConfig: |
+    {
+      "disable_remote_exec": true,
+      "disable_update_check": true,
+      "performance": {
+        "raft_multiplier": 10
+      },
+      "ports": {
+        "dns": 8600,
+        "grpc": 8502,
+        "http": 8500,
+        "https": -1
+      },
+      "primary_datacenter": "au-syd1"
+    }
+
+  resources:
+    requests:
+      memory: 256Mi
+      cpu: 100m
+    limits:
+      memory: 2Gi
+      cpu: 1000m
+
+client:
+  enabled: false
+
+ui:
+  enabled: true
+  service:
+    type: ClusterIP
+
+connectInject:
+  enabled: false
+
+dns:
+  enabled: true

apps/overlays/sandbox/consul/kustomization.yaml

@@ -0,0 +1,44 @@
+---
+apiVersion: kustomize.config.k8s.io/v1beta1
+kind: Kustomization
+
+resources:
+  - ../../../base/consul
+
+patches:
+  - target:
+      kind: Namespace
+      name: consul
+    patch: |-
+      - op: replace
+        path: /metadata/name
+        value: sandbox-consul
+  - target:
+      kind: Gateway
+      name: consul
+    patch: |-
+      - op: replace
+        path: /metadata/namespace
+        value: sandbox-consul
+  - target:
+      kind: HTTPRoute
+      name: consul
+    patch: |-
+      - op: replace
+        path: /metadata/namespace
+        value: sandbox-consul
+  - target:
+      kind: PodDisruptionBudget
+      name: consul-server
+    patch: |-
+      - op: replace
+        path: /apiVersion
+        value: policy/v1
+
+helmCharts:
+  - name: consul
+    repo: https://helm.releases.hashicorp.com
+    version: "1.9.7"
+    releaseName: consul
+    namespace: sandbox-consul
+    valuesFile: values.yaml

apps/overlays/sandbox/consul/values.yaml

@@ -0,0 +1,51 @@
+global:
+  name: consul
+  datacenter: au-syd1
+  domain: consul
+
+server:
+  image: hashicorp/consul:1.22.7
+  replicas: 5
+  bootstrapExpect: 5
+  storage: 10Gi
+  storageClass: cephrbd-fast-delete
+
+  connect: true
+
+  extraConfig: |
+    {
+      "disable_remote_exec": true,
+      "disable_update_check": true,
+      "performance": {
+        "raft_multiplier": 10
+      },
+      "ports": {
+        "dns": 8600,
+        "grpc": 8502,
+        "http": 8500,
+        "https": -1
+      },
+      "primary_datacenter": "au-syd1"
+    }
+
+  resources:
+    requests:
+      memory: 256Mi
+      cpu: 100m
+    limits:
+      memory: 2Gi
+      cpu: 1000m
+
+client:
+  enabled: false
+
+ui:
+  enabled: true
+  service:
+    type: ClusterIP
+
+connectInject:
+  enabled: false
+
+dns:
+  enabled: true

argocd/applicationsets/platform.yaml

@@ -15,6 +15,7 @@ spec:
       - path: apps/overlays/*/cert-manager
       - path: apps/overlays/*/certificates
       - path: apps/overlays/*/cnpg-system
+      - path: apps/overlays/*/consul
       - path: apps/overlays/*/elastic-system
       - path: apps/overlays/*/externaldns
       - path: apps/overlays/*/inteldeviceplugins-system