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unkinben a633835550 Enable ACLs on k8s consul with Vault-sourced bootstrap token (#280)
## Why

Phase 1 of the consul VM to k8s migration: bring the k8s consul cluster to ACL parity with the authoritative VM cluster before the eventual snapshot-restore. The VM cluster runs ACLs enabled with `default_policy: deny` and `down_policy: extend-cache`; the k8s cluster currently runs with **ACLs disabled**. Sourcing the bootstrap/management token from Vault lets the k8s cluster bootstrap with the **same** `initial_management` token as the VM cluster, so puppet automation and the snapshot-restore line up. No token material is placed in git.

## Changes

- Enable `global.acls.manageSystemACLs` so the chart manages system ACL tokens/policies for consul components.
- Point `global.acls.bootstrapToken` at a pre-existing Kubernetes secret `consul-bootstrap-acl-token` (key `token`); chart 1.9.7 supports this, and when the secret is populated the `server-acl-init` job **skips bootstrapping** and adopts that token as the management token (renders `-bootstrap-token-secret-name`/`-bootstrap-token-secret-key`, verified in the kustomize output).
- Add a `VaultAuth` (mount `k8s/au/syd1`, role `default`, SA `default`) and `VaultStaticSecret` in the `consul` namespace that sync `kv/kubernetes/namespace/consul/default/bootstrap-acl-token` into the `consul-bootstrap-acl-token` k8s secret via VSO (mirrors the encapi pattern).
- Merge the `acl` block (`enabled`, `default_policy: deny`, `down_policy: extend-cache`, `enable_token_persistence`) into the server `extraConfig` to match the VM posture.

## OPERATIONAL NOTE — required BEFORE merge

The user MUST place the VM cluster's `initial_management` token in Vault first, or ACL bootstrapping will generate a *different* token and break the mirror:

```
vault kv put kv/kubernetes/namespace/consul/default/bootstrap-acl-token token=<VM initial_management token>
```

VSO then syncs it into the `consul-bootstrap-acl-token` secret before the `server-acl-init` job runs. No terraform-vault change is needed: the wildcard `default` k8s-auth role (`bound_service_account_namespaces: ['*']`) plus the templated `kv/kubernetes/default` policy already grant the `consul` namespace `default` SA read on `kv/kubernetes/namespace/consul/default/*`.

## Risk / expected behavior

- Enabling ACLs **rolls the 5 servers** (StatefulSet update) and runs a `server-acl-init` job.
- With `default_policy: deny`, previously-anonymous operations are denied. The `vault` service in the k8s catalog is self-registered by the Vault/OpenBao servers (namespace `vault`) via their `service_registration "consul"` stanza (catalog entry has `ServiceMeta.external-source: vault`, port 8200). After the flip this registration will be **denied** unless Vault is given a Consul ACL token with `service:write` on `vault` (and the anonymous token is not granted that). This must be handled as part of the cutover — either grant the anonymous token limited write, or configure a token in Vault's consul service_registration.
- Anonymous HTTP API reads (e.g. `/v1/status/leader`) will also be denied post-merge unless a token is supplied — see PR 2 verification note.

## Ordering

Independent of the API-route PR (`benvin/consul-api-route`). Both precede phase 3 (snapshot). Do not merge until the Vault step above is done.

Reviewed-on: #280
Co-authored-by: Ben Vincent <ben@unkin.net>
Co-committed-by: Ben Vincent <ben@unkin.net>
2026-07-25 17:39:18 +10:00

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YAML

---
apiVersion: secrets.hashicorp.com/v1beta1
kind: VaultAuth
metadata:
name: default
namespace: consul
spec:
allowedNamespaces:
- consul
kubernetes:
audiences:
- vault
role: default
serviceAccount: default
tokenExpirationSeconds: 600
method: kubernetes
mount: k8s/au/syd1
vaultConnectionRef: vso-system/default