docs(tests): N100 bare-metal physical validation run (R-21) — findings + current state

Supervised clean-slate reinstall of the demo N100 from a pipeline-built Felhom ISO +
onboarding rehearsal. Core objectives GREEN: first-boot chain reached rc-0 on the first
attempt on real hardware (closes slice A's operator-gated boundary), serial-filter safety
proven on metal, PBS-DR reconciler self-healed on the reused peer, DMI verdict -> key on
MAC+UUID. Hard obstacle was firmware not the pipeline: this cheap AMI AN3PLUS 0.01 board
won't UEFI-boot the ISO's GRUB from USB (relocation 0x0; SB-off + shim-bypass don't help),
worked around live with a grub-mkimage loader from the box's own GRUB (slice-B input).
7 findings logged (F1 firmware loader HIGH; F2/F3/F4 reused-customer edges -> R-1/Peti;
F5 guest-RAM, F6 drive-init mount, F7 back-route). Full doc in documentation/tests/;
ROADMAP R-21 + REPORT + CONTEXT updated. No production code changed.

documentation/backlog/ROADMAP.md

@@ -49,7 +49,7 @@
 | R-13 | OOB management arc: dual-use existing WireGuard + hub desired-state channel as mutual-repair | L | idea | |
 | R-14 | Headscale/WireGuard spike: Minecraft/gaming port connectivity (CGNAT-proof, sovereign DERP fallback) | M | idea | |
 | R-15 | Multi-user dashboard accounts (household members, roles) | L | idea | Single password is a stated alpha limitation (R-11) |
-| R-21 | **Bare-metal Felhom ISO** — per-PVE-release auto-install ISO for blank customer hardware → first-boot wrapper (invokes `felhom-host-install.sh`) → claim-code pairing (option C) | XL | **in-progress** (slice A shipped 2026-07-16 — `scripts/iso/`, scripts v1.16.0) | **Slice A (build pipeline + first-boot bootstrap) DONE + validated on VM 310:** build gate/red-proof, disk-filter fail-safe, stub→retry-unit→real public-channel host-install fetch+invoke→retry, resume-decision, exactly-once, no-net retry+recovery all GREEN. Operator-gated remainder: host-install rc-0 terminal success (drill customer needs the password-gated create-UI). **Slice B** = physical N100 RUNBOOK (real DMI/firmware/USB/prior-LVM). **Slice C** = claim-pairing so the *distributed* ISO carries no retrieval passphrase (slice-A ISO is secret-bearing, supervised/single-use). Origin spike `audits/SPIKE-baremetal-iso-2026-07-16.md`: every mechanism GREEN on nested virt (VM 310 on felhom-pve). Zero-touch install BIOS **and** UEFI incl. **Secure Boot enforcing** (no MOK/keypress); first-boot hook `fully-up` = root + working pvesh/pct, exactly-once via `pending-first-boot-setup` flag; post-install **webhook** carries SMBIOS-UUID + management-MAC + host SSH keys → the unclaimed-appliance record; disk-filter installs only the target (canary byte-identical) and **fails-safe** on match-nothing / bad disk; `from-url` + `cert-fingerprint` **fails CLOSED**. OPEN (needs ONE real bare-metal run): vendor DMI serials (empty on virt), real firmware/NIC quirks, a pre-existing-LVM wipe step. Pipeline notes: assistant pairs to the ISO by Debian codename, ~11.5 s/ISO on DooPlex, **gate on `validate-answer` output not `$?`** (exit 0 on failure). Would flip a new capability-map MISSING row "customer self-installs on bare hardware" once spec'd. *(brief called this R-22)* |
+| R-21 | **Bare-metal Felhom ISO** — per-PVE-release auto-install ISO for blank customer hardware → first-boot wrapper (invokes `felhom-host-install.sh`) → claim-code pairing (option C) | XL | **in-progress** (slice A shipped 2026-07-16; physical run 2026-07-16) | **PHYSICAL RUN 2026-07-16 (`tests/VALIDATION-n100-baremetal-2026-07-16.md`):** demo N100 reinstalled clean-slate from a pipeline ISO → chain reached **rc-0 first try on real hardware** (closes slice A's operator-gated boundary), serial-filter safety proven on metal, PBS-DR reconciler self-healed on the reused peer, DMI verdict = key on MAC+UUID. **F1 (HIGH, slice-B input):** this cheap AMI `AN3PLUS 0.01` firmware won't UEFI-boot the ISO's GRUB from USB (`relocation 0x0`) — SB-off/shim-bypass don't help; worked around live with a `grub-mkimage` loader built from the box's own GRUB. Pipeline must ship a firmware-compatible loader / PXE path. Reused-customer edges (F2 claim re-issue, F3 offsite re-issue, F4 non-default-storage-id ACL 403) feed R-1/Peti. UX: F6 drive-init doesn't mount+attach, F5 guest-RAM not configurable, F7 back-route. — **Slice A (build pipeline + first-boot bootstrap) DONE + validated on VM 310:** build gate/red-proof, disk-filter fail-safe, stub→retry-unit→real public-channel host-install fetch+invoke→retry, resume-decision, exactly-once, no-net retry+recovery all GREEN. Operator-gated remainder: host-install rc-0 terminal success (drill customer needs the password-gated create-UI). **Slice B** = physical N100 RUNBOOK (real DMI/firmware/USB/prior-LVM). **Slice C** = claim-pairing so the *distributed* ISO carries no retrieval passphrase (slice-A ISO is secret-bearing, supervised/single-use). Origin spike `audits/SPIKE-baremetal-iso-2026-07-16.md`: every mechanism GREEN on nested virt (VM 310 on felhom-pve). Zero-touch install BIOS **and** UEFI incl. **Secure Boot enforcing** (no MOK/keypress); first-boot hook `fully-up` = root + working pvesh/pct, exactly-once via `pending-first-boot-setup` flag; post-install **webhook** carries SMBIOS-UUID + management-MAC + host SSH keys → the unclaimed-appliance record; disk-filter installs only the target (canary byte-identical) and **fails-safe** on match-nothing / bad disk; `from-url` + `cert-fingerprint` **fails CLOSED**. OPEN (needs ONE real bare-metal run): vendor DMI serials (empty on virt), real firmware/NIC quirks, a pre-existing-LVM wipe step. Pipeline notes: assistant pairs to the ISO by Debian codename, ~11.5 s/ISO on DooPlex, **gate on `validate-answer` output not `$?`** (exit 0 on failure). Would flip a new capability-map MISSING row "customer self-installs on bare hardware" once spec'd. *(brief called this R-22)* |
 
 ## Absorbed / superseded notes in this folder