fix(ci1): switch ISO from filesystem PVC to Block-mode DataVolume
The bootOrder swap alone didn't fix the install — even with `windows-iso` at
bootOrder:1, OVMF UEFI still timed out reading the SATA CDROM:
BdsDxe: starting Boot0001 "UEFI QEMU DVD-ROM QM00001 " from ... Sata(...)
BdsDxe: failed to start Boot0001 ... : Time out
BdsDxe: No bootable option or device was found.
Diagnosis (debug pod mounting the live PVC):
- /pvc/disk.img IS a valid bootable ISO9660 image — `file` reports
"ISO 9660 CD-ROM filesystem data 'SSS_X64FRE_EN-US_DV9' (bootable)".
- bytes 0..15: zeros (NOT QCOW2 magic 51 46 49 fb).
- bytes 32769..32773: "CD001" — ISO9660 primary volume descriptor at the
correct offset.
So content was fine. The bug is in how KubeVirt + QEMU + Longhorn expose a
Filesystem-mode PVC's `/disk.img` as a SATA CDROM. With Block-mode the
underlying volume IS the raw ISO9660 sectors, OVMF reads them directly,
no QEMU file-emulation layer. This is the recommended pattern for ISO
install media on KubeVirt + Longhorn.
Migration:
- Replace `kind: PersistentVolumeClaim` with `kind: DataVolume` (CDI manages
the underlying PVC + upload-target pod).
- Set `pvc.volumeMode: Block`.
- Annotate `cdi.kubevirt.io/storage.contentType: kubevirt` so CDI keeps raw
bytes (no QCOW2 wrap).
- VM volume reference changes from `persistentVolumeClaim.claimName` to
`dataVolume.name`. KubeVirt's VMI controller blocks VM start until DV
phase is Succeeded (upload completed).
Operator step after this lands:
1. Wait for DV `phase: UploadReady`
kubectl get dv -n kubevirt-vms windows-server-2025-iso -w
2. virtctl image-upload dv windows-server-2025-iso -n kubevirt-vms \
--image-path "...\en-us_windows_server_2025...iso" \
--uploadproxy-url https://localhost:8443 --insecure --no-create
3. Re-flip runStrategy to Always (was set to Halted live-side during
migration; this commit keeps the manifest at Always).
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
This commit is contained in:
@@ -49,31 +49,57 @@ metadata:
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pod-security.kubernetes.io/enforce: privileged
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pod-security.kubernetes.io/enforce: privileged
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---
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---
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# ISO PVC — populated via CDI virtctl image-upload (CDI is now installed).
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# ISO DataVolume — CDI manages an underlying PVC of the same name and exposes
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# Population workflow (LIVE 2026-05-08):
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# the upload-target pod once it's ready.
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# 1. virtctl --kubeconfig $env:USERPROFILE\.kube\rke2.yaml image-upload pvc \
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#
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# **Why DataVolume + Block volumeMode** (vs the original `kind: PersistentVolumeClaim`
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# + virtctl image-upload pvc): a `volumeMode: Filesystem` PVC stores the upload
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# as `/disk.img` on a mounted ext4. KubeVirt then exposes that file as a SATA
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# CDROM via QEMU. On 2026-05-08 this caused the OVMF UEFI firmware to fail
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# Boot0001 with "Time out" reading the SATA CDROM, even with the install ISO
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# at bootOrder:1 — see docs/infrastructure/feedback notes below. The ISO
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# content WAS valid (`file` reported "ISO 9660 CD-ROM filesystem data ...
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# (bootable)"), but the QEMU SATA emulation over a Filesystem-PVC backing was
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# too slow / mis-attached for OVMF's CDROM read window.
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#
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# `volumeMode: Block` gives us a raw block device directly — KubeVirt attaches
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# it to the VM as `/dev/sdX` style storage, OVMF reads ISO9660 sectors directly
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# from the underlying block volume, no QEMU virtual file emulation needed.
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# This is the recommended pattern for ISO install media on KubeVirt + Longhorn.
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#
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# Population workflow:
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# 1. After this DataVolume is applied, CDI creates the PVC and an
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# upload-target pod. Wait for `phase: UploadReady`.
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# 2. From BLUEJAY-WS:
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# kubectl --kubeconfig $env:USERPROFILE\.kube\rke2.yaml port-forward \
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# -n cdi service/cdi-uploadproxy 8443:443 &
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# virtctl --kubeconfig $env:USERPROFILE\.kube\rke2.yaml image-upload dv \
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# windows-server-2025-iso -n kubevirt-vms \
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# windows-server-2025-iso -n kubevirt-vms \
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# --image-path "$env:USERPROFILE\Downloads\en-us_windows_server_2025_updated_march_2026_x64_dvd_8e06425a.iso" \
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# --image-path "$env:USERPROFILE\Downloads\en-us_windows_server_2025_updated_march_2026_x64_dvd_8e06425a.iso" \
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# --size 10Gi --storage-class longhorn --access-mode ReadWriteOnce \
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# --uploadproxy-url https://localhost:8443 --insecure --no-create
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# --uploadproxy-url https://cdi-uploadproxy.cdi.svc:443 --insecure
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# (`--no-create` — the DV/PVC already exist, virtctl just streams bytes.)
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# (--uploadproxy-url uses port-forward in practice: see plan doc Phase 1.5.)
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apiVersion: cdi.kubevirt.io/v1beta1
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#
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kind: DataVolume
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# Note: CDI's PVC creation hooks add cdi.kubevirt.io/storage.* annotations
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# automatically. The ISO source file is 7.7GB → request 10Gi for headroom.
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apiVersion: v1
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kind: PersistentVolumeClaim
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metadata:
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metadata:
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name: windows-server-2025-iso
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name: windows-server-2025-iso
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namespace: kubevirt-vms
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namespace: kubevirt-vms
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labels:
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labels:
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app: ci-runner
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app: ci-runner
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flowercore.io/managed-by: bluejay-infra
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flowercore.io/managed-by: bluejay-infra
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annotations:
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# Tell CDI not to "convert" — keep raw bytes so the underlying block device
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# IS the ISO9660 sectors verbatim, not a QCOW2 wrap.
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cdi.kubevirt.io/storage.contentType: kubevirt
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spec:
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spec:
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source:
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upload: {}
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pvc:
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accessModes:
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accessModes:
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- ReadWriteOnce # Bump to ReadOnlyMany after population for multi-VM use
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- ReadWriteOnce # Bump to ReadOnlyMany after population for multi-VM use
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resources:
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resources:
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requests:
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requests:
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storage: 10Gi # Bumped from 6Gi (Server 2025 ISO is 7.7GB)
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storage: 10Gi # Server 2025 ISO is 7.7GB; 10Gi for headroom
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volumeMode: Block # CRITICAL — see header comment above
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storageClassName: longhorn
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storageClassName: longhorn
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---
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---
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@@ -384,8 +410,11 @@ spec:
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persistentVolumeClaim:
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persistentVolumeClaim:
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claimName: ci1-rootdisk
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claimName: ci1-rootdisk
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- name: windows-iso
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- name: windows-iso
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persistentVolumeClaim:
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# Reference the DataVolume (defined above) — CDI creates the PVC of
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claimName: windows-server-2025-iso
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# the same name with volumeMode: Block. The VMI controller blocks
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# VM start until DV phase is Succeeded (i.e. upload completed).
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dataVolume:
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name: windows-server-2025-iso
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- name: virtio-drivers
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- name: virtio-drivers
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containerDisk:
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containerDisk:
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# Pinned to v1.8.2 (latest stable as of 2026-05-08).
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# Pinned to v1.8.2 (latest stable as of 2026-05-08).
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