Mount the rancher secrets engine + seed a service account + roles

Deploys the Rancher token secrets engine into the cluster, mirroring the litellm
and gpg wiring. The plugin is registered separately (config/plugins) and the
deployer policy is granted separately; this mounts and configures the engine.

- Add rancher_secret_backend module (mount + config via the ranchervaultsecret
  provider): rancher_url https://rancher.k8s.syd1.au.unkin.net.
- Add rancher_secret_backend_service_account module: seeds an auto-rotated token
  (90d TTL / 45d rotation), reading the seed token from KV at
  secret_backend/rancher/service_account/<name> (keys: token, token_name).
- Add rancher_secret_backend_role module + a 'ci' role (1h/8h scoped creds).
- Wire config.hcl discovery, module variables, main.tf module blocks, the
  terragrunt inputs, and the rancher provider in root.hcl.

Prereq: populate kv/service/vault/au/syd1/secret_backend/rancher/service_account/admin
with a live Rancher admin token before apply.

config/config.hcl

@@ -198,6 +198,13 @@ locals {
       })
       if startswith(file_path, "litellm_secret_backend_role/")
     }
+    plugins = {
+      for file_path, content in local.all_configs :
+      trimsuffix(basename(file_path), ".yaml") => merge(content, {
+        name = trimsuffix(basename(file_path), ".yaml")
+      })
+      if startswith(file_path, "plugins/")
+    }
     gpg_secret_backend = {
       for file_path, content in local.all_configs :
       trimsuffix(basename(file_path), ".yaml") => content
@@ -211,5 +218,26 @@ locals {
       })
       if startswith(file_path, "gpg_key/")
     }
+    rancher_secret_backend = {
+      for file_path, content in local.all_configs :
+      trimsuffix(basename(file_path), ".yaml") => content
+      if startswith(file_path, "rancher_secret_backend/")
+    }
+    rancher_secret_backend_service_account = {
+      for file_path, content in local.all_configs :
+      trimsuffix(replace(file_path, "rancher_secret_backend_service_account/", ""), ".yaml") => merge(content, {
+        name    = trimsuffix(basename(file_path), ".yaml")
+        backend = dirname(replace(file_path, "rancher_secret_backend_service_account/", ""))
+      })
+      if startswith(file_path, "rancher_secret_backend_service_account/")
+    }
+    rancher_secret_backend_role = {
+      for file_path, content in local.all_configs :
+      trimsuffix(replace(file_path, "rancher_secret_backend_role/", ""), ".yaml") => merge(content, {
+        name    = trimsuffix(basename(file_path), ".yaml")
+        backend = dirname(replace(file_path, "rancher_secret_backend_role/", ""))
+      })
+      if startswith(file_path, "rancher_secret_backend_role/")
+    }
   }
 }

config/plugins/vault-plugin-secrets-gpg.yaml

@@ -0,0 +1,10 @@
+# config/plugins/vault-plugin-secrets-gpg.yaml
+# Imports (registers) the gpg secrets plugin in the catalog. Filename = catalog
+# name = mount type. The binary is installed on the OpenBao nodes by Puppet
+# (openbao-plugin-secrets-gpg RPM -> /opt/openbao-plugins/vault-plugin-secrets-gpg).
+#
+# sha256 pins the released v0.1.0 binary; bump it in lockstep with any RPM
+# upgrade or OpenBao will refuse to launch the plugin.
+type: secret
+command: vault-plugin-secrets-gpg
+sha256: "0e92d7408795688badb55789bc1604e8f1dd4d71998656c7f831991fce9a7b20"

config/rancher_secret_backend/rancher.yaml

@@ -0,0 +1,8 @@
+# Mounts the rancher token secrets engine at "rancher" and writes its config.
+# The plugin is registered in the catalog separately (see
+# config/plugins/vault-plugin-secrets-rancher.yaml). Seeded service-account
+# tokens live under config/rancher_secret_backend_service_account/rancher/ and
+# roles under config/rancher_secret_backend_role/rancher/.
+description: "Rancher API token engine (seeded root rotation + dynamic scoped creds)"
+rancher_url: "https://rancher.k8s.syd1.au.unkin.net"
+request_timeout_seconds: 30

config/rancher_secret_backend_role/rancher/ci.yaml

@@ -0,0 +1,9 @@
+# A role that mints short-lived Rancher tokens from the "admin" service account.
+# Reading rancher/creds/ci returns a lease-bound token deleted from Rancher on
+# revoke. Minted tokens inherit the admin service account's RBAC; only cluster
+# and TTL are scoped per-token.
+---
+service_account: admin
+description: "CI/CD ephemeral Rancher token"
+ttl: 3600      # seconds (1h)
+max_ttl: 28800 # seconds (8h)

config/rancher_secret_backend_service_account/rancher/admin.yaml

@@ -0,0 +1,8 @@
+# A seeded, auto-rotated Rancher service-account token on the "rancher" engine.
+# The seed token itself is sensitive and read from KV (not stored here):
+#   kv/service/vault/au/syd1/secret_backend/rancher/service_account/admin
+#   -> keys: token (required), token_name (optional)
+# Populate that KV path with a live Rancher admin token BEFORE applying; the
+# engine then rotates it (mints a fresh 90d token every 45d) so it never lapses.
+token_ttl: 7776000       # 90d in seconds
+rotation_period: 3888000 # 45d in seconds

environments/au/syd1/terragrunt.hcl

@@ -70,9 +70,14 @@ inputs = {
   pki_mount_only                 = local.config.pki_mount_only
   litellm_secret_backend         = local.config.litellm_secret_backend
   litellm_secret_backend_role    = local.config.litellm_secret_backend_role
+  plugins                        = local.config.plugins
   gpg_secret_backend             = local.config.gpg_secret_backend
   gpg_key                        = local.config.gpg_key
 
+  rancher_secret_backend                 = local.config.rancher_secret_backend
+  rancher_secret_backend_service_account = local.config.rancher_secret_backend_service_account
+  rancher_secret_backend_role            = local.config.rancher_secret_backend_role
+
   # Pass policy maps to vault_cluster module
   policy_auth_map  = local.policies.policy_auth_map
   policy_rules_map = local.policies.policy_rules_map

environments/root.hcl

@@ -23,6 +23,12 @@ provider "gpg" {
   address = local.vault_addr
 }
 
+# The rancher token secrets engine is managed through its own provider (same
+# Vault server; token falls back to VAULT_TOKEN).
+provider "rancher" {
+  address = local.vault_addr
+}
+
 terraform {
   backend "consul" {
     address = "https://consul.service.consul"
@@ -49,6 +55,10 @@ terraform {
       source  = "artifactapi.k8s.syd1.au.unkin.net/terraform-unkin/gpgvaultsecret"
       version = "0.1.0"
     }
+    rancher = {
+      source  = "artifactapi.k8s.syd1.au.unkin.net/terraform-unkin/ranchervaultsecret"
+      version = "0.1.0"
+    }
   }
 }
 EOF

modules/vault_cluster/main.tf

@@ -334,6 +334,18 @@ module "litellm_secret_backend_role" {
   depends_on = [module.litellm_secret_backend]
 }
 
+module "plugin" {
+  source = "./modules/plugin"
+
+  for_each = var.plugins
+
+  name           = each.value.name
+  type           = each.value.type
+  command        = each.value.command
+  sha256         = each.value.sha256
+  plugin_version = each.value.version
+}
+
 module "gpg_secret_backend" {
   source = "./modules/gpg_secret_backend"
 
@@ -342,6 +354,8 @@ module "gpg_secret_backend" {
   path        = each.key
   plugin      = each.value.plugin
   description = each.value.description
+
+  depends_on = [module.plugin]
 }
 
 module "gpg_key" {
@@ -360,6 +374,53 @@ module "gpg_key" {
   depends_on = [module.gpg_secret_backend]
 }
 
+module "rancher_secret_backend" {
+  source = "./modules/rancher_secret_backend"
+
+  for_each = var.rancher_secret_backend
+
+  path                    = each.key
+  plugin                  = each.value.plugin
+  description             = each.value.description
+  rancher_url             = each.value.rancher_url
+  ca_cert                 = each.value.ca_cert
+  tls_skip_verify         = each.value.tls_skip_verify
+  request_timeout_seconds = each.value.request_timeout_seconds
+
+  depends_on = [module.plugin]
+}
+
+module "rancher_secret_backend_service_account" {
+  source = "./modules/rancher_secret_backend_service_account"
+
+  for_each = var.rancher_secret_backend_service_account
+
+  backend         = each.value.backend
+  name            = each.value.name
+  country         = var.country
+  region          = var.region
+  token_ttl       = each.value.token_ttl
+  rotation_period = each.value.rotation_period
+
+  depends_on = [module.rancher_secret_backend]
+}
+
+module "rancher_secret_backend_role" {
+  source = "./modules/rancher_secret_backend_role"
+
+  for_each = var.rancher_secret_backend_role
+
+  backend         = each.value.backend
+  name            = each.value.name
+  service_account = each.value.service_account
+  cluster_name    = each.value.cluster_name
+  description     = each.value.description
+  ttl             = each.value.ttl
+  max_ttl         = each.value.max_ttl
+
+  depends_on = [module.rancher_secret_backend_service_account]
+}
+
 module "vault_policy" {
   source = "./modules/vault_policy"
 

modules/vault_cluster/modules/plugin/main.tf

@@ -0,0 +1,12 @@
+# Registers ("imports") a plugin binary in the Vault/OpenBao plugin catalog so
+# it can be mounted. The binary must already exist in the server
+# plugin_directory (installed out of band, e.g. by Puppet); `command` is its
+# filename there. The sha256 must match the on-disk binary or the server refuses
+# to launch the plugin.
+resource "vault_plugin" "this" {
+  type    = var.type
+  name    = var.name
+  command = coalesce(var.command, var.name)
+  sha256  = var.sha256
+  version = var.plugin_version
+}

modules/vault_cluster/modules/plugin/terraform.tf

@@ -0,0 +1,9 @@
+terraform {
+  required_version = ">= 1.10"
+  required_providers {
+    vault = {
+      source  = "hashicorp/vault"
+      version = "5.6.0"
+    }
+  }
+}

modules/vault_cluster/modules/plugin/variables.tf

@@ -0,0 +1,27 @@
+variable "name" {
+  description = "Name to register the plugin under in the catalog (also the mount type)"
+  type        = string
+}
+
+variable "type" {
+  description = "Plugin type: secret, auth or database"
+  type        = string
+  default     = "secret"
+}
+
+variable "command" {
+  description = "Plugin binary filename relative to the server plugin_directory. Defaults to the plugin name."
+  type        = string
+  default     = null
+}
+
+variable "sha256" {
+  description = "SHA-256 of the installed plugin binary; must match the on-disk binary"
+  type        = string
+}
+
+variable "plugin_version" {
+  description = "Optional plugin version to register the catalog entry under"
+  type        = string
+  default     = null
+}

modules/vault_cluster/modules/rancher_secret_backend/main.tf

@@ -0,0 +1,13 @@
+# Mounts the rancher secrets engine and writes its connection config via the
+# ranchervaultsecret provider. The plugin is registered ("imported") in the
+# catalog separately (config/plugins/vault-plugin-secrets-rancher.yaml). Seeded
+# service-account tokens and roles are managed by the sibling modules.
+resource "rancher_secret_backend" "this" {
+  path                    = var.path
+  plugin                  = var.plugin
+  description             = var.description
+  rancher_url             = var.rancher_url
+  ca_cert                 = var.ca_cert
+  tls_skip_verify         = var.tls_skip_verify
+  request_timeout_seconds = var.request_timeout_seconds
+}

modules/vault_cluster/modules/rancher_secret_backend/terraform.tf

@@ -0,0 +1,9 @@
+terraform {
+  required_version = ">= 1.10"
+  required_providers {
+    rancher = {
+      source  = "artifactapi.k8s.syd1.au.unkin.net/terraform-unkin/ranchervaultsecret"
+      version = "0.1.0"
+    }
+  }
+}

modules/vault_cluster/modules/rancher_secret_backend/variables.tf

@@ -0,0 +1,39 @@
+variable "path" {
+  description = "Mount path of the rancher secrets engine (e.g. \"rancher\")"
+  type        = string
+}
+
+variable "plugin" {
+  description = "Registered plugin name to mount (the catalog name = mount type)"
+  type        = string
+  default     = "vault-plugin-secrets-rancher"
+}
+
+variable "description" {
+  description = "Human-friendly description of the mount"
+  type        = string
+  default     = null
+}
+
+variable "rancher_url" {
+  description = "Base URL of the Rancher server (e.g. https://rancher.k8s.syd1.au.unkin.net)"
+  type        = string
+}
+
+variable "ca_cert" {
+  description = "PEM CA certificate that signed the Rancher server's TLS cert (optional; omit to use the system trust store)"
+  type        = string
+  default     = null
+}
+
+variable "tls_skip_verify" {
+  description = "Skip TLS verification of the Rancher server (not recommended)"
+  type        = bool
+  default     = false
+}
+
+variable "request_timeout_seconds" {
+  description = "HTTP timeout in seconds for calls from the plugin to Rancher"
+  type        = number
+  default     = 30
+}

modules/vault_cluster/modules/rancher_secret_backend_role/main.tf

@@ -0,0 +1,11 @@
+# A role that mints short-lived, optionally cluster-scoped rancher tokens from a
+# service account. Reading rancher/creds/<name> produces a lease-bound token.
+resource "rancher_secret_backend_role" "this" {
+  backend         = var.backend
+  name            = var.name
+  service_account = var.service_account
+  cluster_name    = var.cluster_name
+  description     = var.description
+  ttl             = var.ttl
+  max_ttl         = var.max_ttl
+}

modules/vault_cluster/modules/rancher_secret_backend_role/terraform.tf

@@ -0,0 +1,9 @@
+terraform {
+  required_version = ">= 1.10"
+  required_providers {
+    rancher = {
+      source  = "artifactapi.k8s.syd1.au.unkin.net/terraform-unkin/ranchervaultsecret"
+      version = "0.1.0"
+    }
+  }
+}

modules/vault_cluster/modules/rancher_secret_backend_role/variables.tf

@@ -0,0 +1,38 @@
+variable "backend" {
+  description = "Mount path of the rancher secrets engine this role lives on"
+  type        = string
+}
+
+variable "name" {
+  description = "Role name"
+  type        = string
+}
+
+variable "service_account" {
+  description = "Service account (seeded token) used to mint credentials; its user's RBAC is inherited by minted tokens"
+  type        = string
+}
+
+variable "cluster_name" {
+  description = "Downstream cluster to scope minted tokens to (empty = full Rancher-server scope)"
+  type        = string
+  default     = null
+}
+
+variable "description" {
+  description = "Description applied to each minted Rancher token"
+  type        = string
+  default     = null
+}
+
+variable "ttl" {
+  description = "Default lease TTL in seconds for tokens minted from this role"
+  type        = number
+  default     = null
+}
+
+variable "max_ttl" {
+  description = "Maximum lease TTL in seconds for tokens minted from this role"
+  type        = number
+  default     = null
+}

modules/vault_cluster/modules/rancher_secret_backend_service_account/main.tf

@@ -0,0 +1,18 @@
+# Seeds an auto-rotated rancher service-account token. The seed token is
+# sensitive and read from KV, not stored in git:
+#   kv/service/vault/<country>/<region>/secret_backend/<backend>/service_account/<name>
+# Expected keys: token (required), token_name (optional, the ext.cattle.io Token
+# metadata.name so the engine can delete the seed after the first rotation).
+data "vault_kv_secret_v2" "seed" {
+  mount = "kv"
+  name  = "service/vault/${var.country}/${var.region}/secret_backend/${var.backend}/service_account/${var.name}"
+}
+
+resource "rancher_secret_backend_service_account" "this" {
+  backend         = var.backend
+  name            = var.name
+  token           = data.vault_kv_secret_v2.seed.data["token"]
+  token_name      = lookup(data.vault_kv_secret_v2.seed.data, "token_name", null)
+  token_ttl       = var.token_ttl
+  rotation_period = var.rotation_period
+}

modules/vault_cluster/modules/rancher_secret_backend_service_account/terraform.tf

@@ -0,0 +1,13 @@
+terraform {
+  required_version = ">= 1.10"
+  required_providers {
+    vault = {
+      source  = "hashicorp/vault"
+      version = "5.6.0"
+    }
+    rancher = {
+      source  = "artifactapi.k8s.syd1.au.unkin.net/terraform-unkin/ranchervaultsecret"
+      version = "0.1.0"
+    }
+  }
+}

modules/vault_cluster/modules/rancher_secret_backend_service_account/variables.tf

@@ -0,0 +1,31 @@
+variable "backend" {
+  description = "Mount path of the rancher secrets engine this service account lives on"
+  type        = string
+}
+
+variable "name" {
+  description = "Service-account name"
+  type        = string
+}
+
+variable "country" {
+  description = "Country code, used to locate the seed token in KV"
+  type        = string
+}
+
+variable "region" {
+  description = "Region code, used to locate the seed token in KV"
+  type        = string
+}
+
+variable "token_ttl" {
+  description = "Lifetime in seconds requested for each rotated replacement token (default: engine default, 90d)"
+  type        = number
+  default     = null
+}
+
+variable "rotation_period" {
+  description = "Seconds a token is used before rotation (default: engine default, 45d). Must be < token_ttl"
+  type        = number
+  default     = null
+}

modules/vault_cluster/variables.tf

@@ -315,6 +315,18 @@ variable "litellm_secret_backend_role" {
   default = {}
 }
 
+variable "plugins" {
+  description = "Map of plugins to import (register) in the catalog, keyed by catalog name"
+  type = map(object({
+    name    = string
+    type    = optional(string, "secret")
+    command = optional(string)
+    sha256  = string
+    version = optional(string)
+  }))
+  default = {}
+}
+
 variable "gpg_secret_backend" {
   description = "Map of GPG/OpenPGP secret engines to mount (path => registered plugin + description). The plugin is registered separately via config/plugins."
   type = map(object({
@@ -338,6 +350,44 @@ variable "gpg_key" {
   default = {}
 }
 
+variable "rancher_secret_backend" {
+  description = "Map of rancher token secret engines to create (mount + config)"
+  type = map(object({
+    plugin                  = optional(string, "vault-plugin-secrets-rancher")
+    description             = optional(string)
+    rancher_url             = string
+    ca_cert                 = optional(string)
+    tls_skip_verify         = optional(bool, false)
+    request_timeout_seconds = optional(number, 30)
+  }))
+  default = {}
+}
+
+variable "rancher_secret_backend_service_account" {
+  description = "Map of seeded, auto-rotated rancher service-account tokens (seed token read from KV)"
+  type = map(object({
+    name            = string
+    backend         = string
+    token_ttl       = optional(number)
+    rotation_period = optional(number)
+  }))
+  default = {}
+}
+
+variable "rancher_secret_backend_role" {
+  description = "Map of rancher token-minting roles to create"
+  type = map(object({
+    name            = string
+    backend         = string
+    service_account = string
+    cluster_name    = optional(string)
+    description     = optional(string)
+    ttl             = optional(number)
+    max_ttl         = optional(number)
+  }))
+  default = {}
+}
+
 variable "policy_auth_map" {
   description = "Map of auth mounts -> auth roles -> policy names"
   type        = map(map(list(string)))

policies/gpg/admin.yaml

@@ -0,0 +1,35 @@
+# Allow the vault deployer to import the gpg plugin and manage its OpenPGP keys.
+#
+# terraform-vault registers the plugin itself (vault_plugin -> sys/plugins/catalog,
+# a sudo-protected path) and manages keys via the gpgvaultsecret provider, so the
+# deployer needs catalog access on top of the mount access it already has
+# (sys/mounts/*). Without this, apply 403s on the plugin registration and on
+# gpg/keys writes.
+---
+rules:
+  # Import / register (and deregister) the gpg plugin in the catalog.
+  - path: "sys/plugins/catalog/secret/vault-plugin-secrets-gpg"
+    capabilities:
+      - create
+      - read
+      - update
+      - delete
+      - sudo
+  # Manage keys (create/rotate/config/delete) in the gpg mount.
+  - path: "gpg/keys/*"
+    capabilities:
+      - create
+      - read
+      - update
+      - delete
+      - list
+  - path: "gpg/keys"
+    capabilities:
+      - read
+      - list
+
+auth:
+  approle:
+    - tf_vault
+  k8s/au/syd1:
+    - woodpecker_terraform_vault