v0.53.1: refresh recovery units on periodic cache cycle (idempotent)

CaptureRecoveryUnit now builds content in memory and skips writes when the unit
is already current (checksum + dump-set + version), so it can run from RefreshCache
(startup + every 5m) without thrashing the USB drive. Units now exist shortly after
startup and track config changes without waiting for the daily DB dump. +idempotency test.

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>

controller/internal/backup/backup.go

@@ -487,6 +487,10 @@ func (m *Manager) RefreshCache(nextDBDump time.Time) {
 	// Discover app data — all deployed stacks, backup is mandatory
 	if m.stackProvider != nil {
 		status.AppDataInfo = DiscoverAppData(m.stackProvider, status.DiscoveredDBs)
+		// Phase 2: keep each app's recovery unit current with its definition. Idempotent
+		// (checksum-skip), so this periodic refresh only writes when the config actually changed,
+		// and ensures units exist shortly after startup without waiting for the daily DB dump.
+		m.captureAllRecoveryUnits()
 	}
 
 	// Fill in dynamic fields under lock.

controller/internal/backup/recovery_unit.go

@@ -56,6 +56,10 @@ func (m *Manager) SetVersion(v string) {
 // CaptureRecoveryUnit writes/refreshes an app's secret-free recovery unit: it captures the
 // compose + metadata + a secret-stripped app.yaml into compose/, enumerates the DB/volume dumps
 // already present, and writes manifest.json. It NEVER writes a secret value or the Docker image.
+//
+// Idempotent: it builds the captured content in memory first and SKIPS all writes when the unit is
+// already current (same config checksums, same dump set, same controller version) — so it can run on
+// the periodic status refresh without thrashing a spinning USB drive.
 func (m *Manager) CaptureRecoveryUnit(stackName string) error {
 	if m.stackProvider == nil {
 		return fmt.Errorf("no stack provider")
@@ -69,41 +73,60 @@ func (m *Manager) CaptureRecoveryUnit(stackName string) error {
 		return fmt.Errorf("cannot determine absolute drive path for %s", stackName)
 	}
 	nsRoot := m.namespaceRoot(drivePath)
+
+	// Build the captured config CONTENT in memory (no writes yet) so we can checksum-compare.
+	type capFile struct {
+		name string
+		data []byte
+		perm os.FileMode
+	}
+	var files []capFile
+	checksums := make(map[string]string)
+	var configFiles []string
+	for _, fname := range []string{"docker-compose.yml", ".felhom.yml"} {
+		data, err := os.ReadFile(filepath.Join(info.StackDir, fname))
+		if err != nil {
+			continue // optional — capture whichever exist
+		}
+		files = append(files, capFile{fname, data, 0644})
+		checksums[fname] = sha256Hex(data)
+		configFiles = append(configFiles, fname)
+	}
+	appYaml := buildStrippedAppYaml(info)
+	files = append(files, capFile{"app.yaml", appYaml, 0600})
+	checksums["app.yaml"] = sha256Hex(appYaml)
+	configFiles = append(configFiles, "app.yaml")
+
+	dbDumps := listFileNames(AppDBDumpPath(nsRoot, stackName), ".sql")
+	volDumps := listFileNames(AppVolumeDumpPath(nsRoot, stackName), ".tar")
+	version := m.versionLocked()
+
+	manifestPath := RecoveryUnitManifestPath(nsRoot, stackName)
+
+	// Skip if the unit is already current — avoids needless drive writes on the periodic refresh.
+	if cur := readManifest(manifestPath); cur != nil &&
+		cur.ControllerVer == version &&
+		stringMapEqual(cur.Checksums, checksums) &&
+		stringSliceEqual(cur.DBDumps, dbDumps) &&
+		stringSliceEqual(cur.VolumeDumps, volDumps) {
+		return nil
+	}
+
 	composeDir := RecoveryUnitComposePath(nsRoot, stackName)
 	if err := os.MkdirAll(composeDir, 0755); err != nil {
 		return fmt.Errorf("creating recovery-unit compose dir: %w", err)
 	}
-
-	checksums := make(map[string]string)
-	var configFiles []string
-
-	// Capture docker-compose.yml + .felhom.yml verbatim (whichever exist).
-	for _, fname := range []string{"docker-compose.yml", ".felhom.yml"} {
-		src := filepath.Join(info.StackDir, fname)
-		if _, err := os.Stat(src); err != nil {
-			continue
+	for _, f := range files {
+		if err := atomicWrite(filepath.Join(composeDir, f.name), f.data, f.perm); err != nil {
+			return fmt.Errorf("capturing %s: %w", f.name, err)
 		}
-		sum, err := copyFileChecksum(src, filepath.Join(composeDir, fname))
-		if err != nil {
-			return fmt.Errorf("capturing %s: %w", fname, err)
-		}
-		checksums[fname] = sum
-		configFiles = append(configFiles, fname)
 	}
 
-	// Write the SECRET-STRIPPED app.yaml (non-secret env only).
-	sum, err := writeStrippedAppYaml(filepath.Join(composeDir, "app.yaml"), info)
-	if err != nil {
-		return fmt.Errorf("writing stripped app.yaml: %w", err)
-	}
-	checksums["app.yaml"] = sum
-	configFiles = append(configFiles, "app.yaml")
-
 	manifest := &RecoveryManifest{
 		SchemaVersion:  1,
 		AppName:        stackName,
 		DisplayName:    info.DisplayName,
-		ControllerVer:  m.versionLocked(),
+		ControllerVer:  version,
 		CreatedAt:      time.Now().UTC().Format(time.RFC3339),
 		Drive:          drivePath,
 		NamespaceRoot:  nsRoot,
@@ -112,11 +135,11 @@ func (m *Manager) CaptureRecoveryUnit(stackName string) error {
 		DataKeyEnvVars: info.DataKeyEnvVars,
 		SecretSource:   "guest app.yaml (live rootfs) or PBS whole-guest snapshot — never stored in this unit",
 		ConfigFiles:    configFiles,
-		DBDumps:        listFileNames(AppDBDumpPath(nsRoot, stackName), ".sql"),
-		VolumeDumps:    listFileNames(AppVolumeDumpPath(nsRoot, stackName), ".tar"),
+		DBDumps:        dbDumps,
+		VolumeDumps:    volDumps,
 		Checksums:      checksums,
 	}
-	if err := writeManifest(RecoveryUnitManifestPath(nsRoot, stackName), manifest); err != nil {
+	if err := writeManifest(manifestPath, manifest); err != nil {
 		return fmt.Errorf("writing manifest: %w", err)
 	}
 
@@ -154,11 +177,13 @@ type strippedAppYaml struct {
 	Env      map[string]string `yaml:"env"`
 }
 
-// writeStrippedAppYaml writes a secret-free app.yaml (non-secret env only) and returns its sha256.
-func writeStrippedAppYaml(dst string, info RecoveryInfo) (string, error) {
+// buildStrippedAppYaml renders a secret-free app.yaml (non-secret env only) as bytes. Deterministic:
+// yaml.v3 sorts map keys and the secret-name list comes in stable metadata order, so identical input
+// yields identical bytes (needed for the checksum-skip guard).
+func buildStrippedAppYaml(info RecoveryInfo) []byte {
 	body, err := yaml.Marshal(strippedAppYaml{Deployed: true, Env: info.NonSecretEnv})
 	if err != nil {
-		return "", err
+		body = []byte("deployed: true\nenv: {}\n")
 	}
 	header := "# Captured by felhom-controller recovery unit — SECRET-FREE.\n" +
 		"# Secret/data-key values are intentionally omitted; recover them at restore from the\n" +
@@ -166,12 +191,7 @@ func writeStrippedAppYaml(dst string, info RecoveryInfo) (string, error) {
 	if len(info.SecretEnvVars) > 0 {
 		header += "#   " + strings.Join(info.SecretEnvVars, ", ") + "\n"
 	}
-	content := []byte(header + string(body))
-	if err := atomicWrite(dst, content, 0600); err != nil {
-		return "", err
-	}
-	sum := sha256.Sum256(content)
-	return hex.EncodeToString(sum[:]), nil
+	return []byte(header + string(body))
 }
 
 // writeManifest writes the manifest JSON atomically.
@@ -183,17 +203,46 @@ func writeManifest(dst string, manifest *RecoveryManifest) error {
 	return atomicWrite(dst, append(data, '\n'), 0644)
 }
 
-// copyFileChecksum copies src→dst and returns the sha256 of the copied bytes.
-func copyFileChecksum(src, dst string) (string, error) {
-	data, err := os.ReadFile(src)
+// readManifest reads an existing recovery-unit manifest (nil if absent or unparseable).
+func readManifest(path string) *RecoveryManifest {
+	data, err := os.ReadFile(path)
 	if err != nil {
-		return "", err
+		return nil
 	}
-	if err := atomicWrite(dst, data, 0644); err != nil {
-		return "", err
+	var m RecoveryManifest
+	if json.Unmarshal(data, &m) != nil {
+		return nil
 	}
+	return &m
+}
+
+func sha256Hex(data []byte) string {
 	sum := sha256.Sum256(data)
-	return hex.EncodeToString(sum[:]), nil
+	return hex.EncodeToString(sum[:])
+}
+
+func stringMapEqual(a, b map[string]string) bool {
+	if len(a) != len(b) {
+		return false
+	}
+	for k, v := range a {
+		if b[k] != v {
+			return false
+		}
+	}
+	return true
+}
+
+func stringSliceEqual(a, b []string) bool {
+	if len(a) != len(b) {
+		return false
+	}
+	for i := range a {
+		if a[i] != b[i] {
+			return false
+		}
+	}
+	return true
 }
 
 // listFileNames returns the names of files with the given suffix in dir (sorted, none if absent).

controller/internal/backup/recovery_unit_test.go

@@ -126,6 +126,52 @@ func TestCaptureRecoveryUnitIsSecretFree(t *testing.T) {
 	})
 }
 
+// TestCaptureRecoveryUnitIdempotent proves the checksum-skip guard: a second capture with unchanged
+// config does NOT rewrite the manifest (CreatedAt stable), but a config change DOES.
+func TestCaptureRecoveryUnitIdempotent(t *testing.T) {
+	tmp := t.TempDir()
+	stackDir := filepath.Join(tmp, "stack")
+	drive := filepath.Join(tmp, "drive")
+	mustWrite(t, filepath.Join(stackDir, "docker-compose.yml"), "services:\n  app:\n    image: ex/app:1\n")
+	mustWrite(t, filepath.Join(AppDBDumpPath(drive, "ex"), "ex.sql"), "d")
+
+	info := RecoveryInfo{StackDir: stackDir, DisplayName: "Ex", ImagePins: []string{"ex/app:1"},
+		NonSecretEnv: map[string]string{"SUBDOMAIN": "ex"}}
+	m := &Manager{logger: log.New(io.Discard, "", 0), systemDataPath: filepath.Join(tmp, "sys"),
+		stackProvider: &fakeRecoveryProvider{info: info, hdd: drive}, version: "v1"}
+
+	manifestPath := RecoveryUnitManifestPath(drive, "ex")
+	if err := m.CaptureRecoveryUnit("ex"); err != nil {
+		t.Fatal(err)
+	}
+	first := readManifest(manifestPath)
+	if first == nil {
+		t.Fatal("manifest not written")
+	}
+
+	// Second capture, unchanged → skipped (manifest byte-identical incl. CreatedAt).
+	if err := m.CaptureRecoveryUnit("ex"); err != nil {
+		t.Fatal(err)
+	}
+	if again := readManifest(manifestPath); again.CreatedAt != first.CreatedAt {
+		t.Errorf("idempotent capture rewrote manifest: %q -> %q", first.CreatedAt, again.CreatedAt)
+	}
+
+	// Change the compose → must rewrite (config checksum differs).
+	mustWrite(t, filepath.Join(stackDir, "docker-compose.yml"), "services:\n  app:\n    image: ex/app:2\n")
+	m.stackProvider.(*fakeRecoveryProvider).info.ImagePins = []string{"ex/app:2"}
+	if err := m.CaptureRecoveryUnit("ex"); err != nil {
+		t.Fatal(err)
+	}
+	changed := readManifest(manifestPath)
+	if len(changed.ImagePins) != 1 || changed.ImagePins[0] != "ex/app:2" {
+		t.Errorf("config change not captured: %v", changed.ImagePins)
+	}
+	if changed.Checksums["docker-compose.yml"] == first.Checksums["docker-compose.yml"] {
+		t.Errorf("compose checksum should change after edit")
+	}
+}
+
 func mustWrite(t *testing.T, path, content string) {
 	t.Helper()
 	if err := os.MkdirAll(filepath.Dir(path), 0755); err != nil {