trails/docs/deployment.md

Deployment runbook

trails.cool runs on two Hetzner hosts. This document covers what an operator needs to know beyond the CLAUDE.md summary.

Hosts

Role	Host	IPs	SSH
Flagship (Cloud)	trails.cool	public + 10.0.0.2 (vSwitch)	ssh -i ~/.ssh/trails-cool-deploy root@trails.cool
BRouter (Dedicated)	ullrich.is	public 176.9.150.227 + 10.0.1.10 (vSwitch)	ssh -i ~/.ssh/trails-brouter-deploy -p 2232 trails@ullrich.is

Both hosts are in fsn1 (Falkenstein) and joined on Hetzner vSwitch #80672 (VLAN 4000). The flagship's Terraform (infrastructure/terraform/) owns the Cloud Network + subnets + server attachment. The dedicated host's VLAN sub-interface is configured out-of-band via netplan (/etc/netplan/60-trails-vswitch.yaml), because the Robot side isn't in the Hetzner Cloud API.

BRouter host — first-time provisioning

See infrastructure/brouter-host/README.md. The short version:

# As root (one-time firewall allowances):
ufw allow in on enp4s0.4000 from 10.0.0.2 to any port 17777 proto tcp \
  comment 'trails brouter via flagship vSwitch'
ufw allow in on enp4s0.4000 from 10.0.0.2 to any port 8080 proto tcp \
  comment 'trails brouter cadvisor via flagship vSwitch'

# As the trails user:
cd ~/brouter  # created by the first cd-brouter deploy
./download-segments.sh   # ~10 GB, a few minutes on a good connection
docker compose pull
docker compose up -d

Secrets rotation

Tokens (including BROUTER_AUTH_TOKEN):

1. Generate: openssl rand -base64 32
2. Edit: SOPS_AGE_KEY_FILE=~/.config/sops/age/keys.txt sops infrastructure/secrets.app.env
3. Commit + push + merge → cd-apps redeploys the Planner with the new token.
4. Touch anything under infrastructure/brouter-host/ (or run gh workflow run cd-brouter.yml) → cd-brouter redeploys the Caddy sidecar with the new token.
5. Brief overlap window where Planner sends new token while Caddy still checks the old value. Both redeploys should complete within a minute of each other; in the worst case a few Planner requests get 403 and retry.

SOPS on macOS looks for the age key at ~/Library/Application Support/sops/age/keys.txt by default. If yours lives under XDG-standard ~/.config/sops/age/keys.txt, set SOPS_AGE_KEY_FILE as above or export it in your shell rc.

Cutover procedure (flagship BRouter → dedicated host)

This is how BROUTER_URL gets flipped. Do it once the dedicated host is provisioned, segments are seeded, and the compose project is up.

1. Pre-flight: curl -sfH "X-BRouter-Auth: $(sops -d infrastructure/secrets.app.env | grep ^BROUTER_AUTH_TOKEN= | cut -d= -f2-)" http://10.0.1.10:17777/brouter?lonlats=11.58,48.13\|11.59,48.14\&profile=trekking\&alternativeidx=0\&format=gpx from the flagship. Expect 200 with GPX. Then curl without the header — expect 403.
2. Wire the token without flipping the URL. Edit SOPS: sops infrastructure/secrets.app.env — the BROUTER_AUTH_TOKEN is already in there. If BROUTER_URL isn't in SOPS, skip; the compose has a default. Merge. Planner redeploys; it now sends the header to the flagship BRouter (which ignores it).
3. Flip the URL. In SOPS, add BROUTER_URL=http://10.0.1.10:17777. Merge. cd-apps redeploys the Planner.
4. Monitor. Grafana "BRouter (dedicated host)" dashboard + brouter_request_duration_seconds on the Overview board. Watch for 30 minutes.
5. Rollback (if needed): remove the BROUTER_URL line from SOPS (falls back to the flagship default). Merge; redeploy. The flagship container is still warm during the soak window.
6. Decommission flagship BRouter (after 48 h of clean metrics): remove the brouter: service + ./segments volume from infrastructure/docker-compose.yml. Merge. cd-infra restarts without BRouter. Reclaim ~2 GB of segment volume on the flagship.

Full restart (flagship)

gh workflow run cd-infra.yml -f restart_all=true

Restarts every flagship service. Does NOT touch the BRouter host.

Network-changing deploys (flagship)

Changing options on an existing Docker network (enable_ipv6, subnets, drivers) requires Docker to recreate the network — and a network can only be recreated when no container from any compose project is attached. The flagship has three+ projects sharing trails-shared (production, persistent staging, every PR preview), and the CD workflows only manage their own project, so a network-option change shipped through cd-infra alone WILL deadlock mid-deploy and can leave production down (this is exactly the 2026-06-06/07 outage: postgres stopped for the recreation, the deploy failed on the held network, nothing restarted it for ~9 hours).

The manual procedure, in order, on the flagship:

cd /opt/trails-cool
# 1. Free trails-shared: down every preview + persistent staging
docker compose ls --filter name=trails-pr- --format json   # enumerate previews
docker compose -f docker-compose.staging.yml -p trails-pr-<N> --env-file staging-pr-<N>.env down
docker compose -f docker-compose.staging.yml -p trails-staging --env-file staging.env --profile persistent down
# 2. Recreate networks via the production project
docker compose --env-file app.env down
docker compose --env-file app.env up -d
# 3. Bring staging + previews back
docker compose -f docker-compose.staging.yml -p trails-staging --env-file staging.env --profile persistent up -d
docker compose -f docker-compose.staging.yml -p trails-pr-<N> --env-file staging-pr-<N>.env up -d
# 4. Verify
docker network inspect trails-cool_default trails-shared --format '{{.Name}} ipv6={{.EnableIPv6}}'
curl -sf https://trails.cool/api/health && curl -sf https://staging.trails.cool/api/health

Plan it as a short maintenance window (~2–3 min downtime); don't ship network-option changes expecting the workflows to apply them.

cd-brouter manual trigger

gh workflow run cd-brouter.yml

Useful to redeploy the BRouter host after token rotation or a config change, without needing a real source change under infrastructure/brouter-host/.