RuBiCK · RuBiCK · Jun 15, 2026 · Jun 15, 2026 · Jun 15, 2026 · Jun 15, 2026
diff --git a/.github/workflows/zarf-lint.yml b/.github/workflows/zarf-lint.yml
@@ -0,0 +1,50 @@
+name: Zarf Lint
+
+on:
+  pull_request:
+    paths:
+      - "zarf.yaml"
+      - "helm/airgapped-demo/**"
+  push:
+    branches: [main]
+    paths:
+      - "zarf.yaml"
+      - "helm/airgapped-demo/**"
+
+jobs:
+  lint:
+    name: Zarf dev lint
+    runs-on: ubuntu-latest
+
+    permissions:
+      contents: read
+
+    steps:
+      - name: Checkout
+        uses: actions/checkout@v4
+
+      - name: Install Zarf
+        run: |
+          curl -sL "https://github.com/zarf-dev/zarf/releases/download/v0.78.0/zarf_v0.78.0_Linux_amd64" \
+            -o /usr/local/bin/zarf
+          chmod +x /usr/local/bin/zarf
+          zarf version
+
+      # ── Lint the package definition ──────────────────────────────────────────
+      # zarf dev lint validates:
+      #   - zarf.yaml schema and required fields
+      #   - chart paths exist and are readable
+      #   - variables are properly declared
+      #   - image references use valid template syntax
+      #
+      # It does NOT pull images or require registry credentials — safe to run on
+      # every PR with no secrets needed.
+      - name: Lint zarf.yaml
+        run: zarf dev lint .
+
+      - name: Summary
+        if: always()
+        run: |
+          echo "### Zarf lint result" >> $GITHUB_STEP_SUMMARY
+          echo "Validated \`zarf.yaml\` and \`helm/airgapped-demo\` chart." >> $GITHUB_STEP_SUMMARY
+          echo "No images were pulled — this check requires no registry credentials." >> $GITHUB_STEP_SUMMARY
diff --git a/.github/workflows/zarf-package.yml b/.github/workflows/zarf-package.yml
@@ -82,3 +82,129 @@ jobs:
           echo "**Image tag:** \`${{ steps.tag.outputs.value }}\`" >> $GITHUB_STEP_SUMMARY
           echo "**Registry:** \`${{ steps.login-ecr.outputs.registry }}\`" >> $GITHUB_STEP_SUMMARY
           ls -lh zarf-package-*.tar.zst >> $GITHUB_STEP_SUMMARY
+
+  # ── Deploy to airgapped cluster ───────────────────────────────────────────────
+  #
+  # TODO: In a real air-gap scenario this step cannot run directly from the CI
+  # runner — the cluster has no internet path back. Two recommended approaches:
+  #
+  #   Option A — Object storage handoff:
+  #     Upload the tarball to S3 (or equivalent), grant the target environment
+  #     read-only access to that bucket (IAM role or signed URL), and pull from
+  #     there. The cluster side never needs outbound internet; only the S3 endpoint
+  #     needs to be reachable (or proxied) from within the air-gap.
+  #
+  #   Option B — Offline USB transfer:
+  #     Download the artifact from the GitHub Actions run, copy it to a USB drive
+  #     together with the Zarf binary and the init package, then deploy from the
+  #     drive on the target machine. See ZARF.md § "Air-Gap USB Deployment".
+  #
+  # For now this job deploys to the lab cluster directly (the runner can reach it
+  # via a self-hosted runner or VPN). Replace with Option A/B for production.
+  #
+  deploy:
+    name: Deploy to Airgapped Cluster
+    runs-on: ubuntu-latest
+    needs: package
+    # Guard: only deploy automatically on workflow_run (post-merge); skip on
+    # manual dispatch unless explicitly set. Remove this condition once Option A
+    # or B is implemented and the step is fully automated.
+    if: ${{ github.event_name == 'workflow_run' && github.event.workflow_run.conclusion == 'success' }}
+
+    permissions:
+      contents: read
+      id-token: write
+      actions: read   # required to download artifacts from the package job
+
+    steps:
+      - name: Checkout
+        uses: actions/checkout@v4
+
+      # ── Recompute the tag (same logic as package job) ────────────────────────
+      - name: Compute image tag
+        id: tag
+        run: |
+          SHORT_SHA=$(echo "${{ github.event.workflow_run.head_sha }}" | cut -c1-7)
+          echo "value=sha-${SHORT_SHA}" >> $GITHUB_OUTPUT
+
+      # ── Download the tarball produced by the package job ─────────────────────
+      - name: Download Zarf package artifact
+        uses: actions/download-artifact@v4
+        with:
+          name: zarf-package-${{ steps.tag.outputs.value }}
+          github-token: ${{ secrets.GITHUB_TOKEN }}
+          run-id: ${{ github.event.workflow_run.id }}
+
+      # ── Install Zarf CLI ─────────────────────────────────────────────────────
+      - name: Install Zarf
+        run: |
+          curl -sL "https://github.com/zarf-dev/zarf/releases/download/v0.78.0/zarf_v0.78.0_Linux_amd64" \
+            -o /usr/local/bin/zarf
+          chmod +x /usr/local/bin/zarf
+          zarf version
+
+      # ── Snapshot: what is running before the deploy ──────────────────────────
+      - name: Pre-deploy state
+        env:
+          KUBECONFIG_B64: ${{ secrets.KUBECONFIG_B64 }}
+        run: |
+          echo "$KUBECONFIG_B64" | base64 -d > /tmp/kubeconfig
+          export KUBECONFIG=/tmp/kubeconfig
+          echo "### Pre-deploy state" >> $GITHUB_STEP_SUMMARY
+          echo '```' >> $GITHUB_STEP_SUMMARY
+          kubectl -n airgapped-demo get deployments \
+            -o custom-columns='NAME:.metadata.name,IMAGE:.spec.template.spec.containers[0].image,READY:.status.readyReplicas' \
+            >> $GITHUB_STEP_SUMMARY 2>&1 || echo "(namespace not yet deployed)" >> $GITHUB_STEP_SUMMARY
+          echo '```' >> $GITHUB_STEP_SUMMARY
+
+      # ── Deploy ───────────────────────────────────────────────────────────────
+      - name: Deploy Zarf package
+        env:
+          KUBECONFIG_B64: ${{ secrets.KUBECONFIG_B64 }}
+        run: |
+          export KUBECONFIG=/tmp/kubeconfig
+          PACKAGE=$(ls zarf-package-*.tar.zst)
+          zarf package deploy "$PACKAGE" --confirm
+
+      # ── Post-deploy fixes: namespace label + registry secret + restart ───────
+      - name: Post-deploy fixes
+        env:
+          KUBECONFIG_B64: ${{ secrets.KUBECONFIG_B64 }}
+          APP_NS: airgapped-demo
+        run: |
+          export KUBECONFIG=/tmp/kubeconfig
+          kubectl label namespace "$APP_NS" zarf.dev/agent=mutate --overwrite
+          kubectl get secret private-registry -n zarf -o json \
+            | python3 -c "import json,sys; d=json.load(sys.stdin); d['metadata']={'name':'private-registry','namespace':'$APP_NS'}; print(json.dumps(d))" \
+            | kubectl apply -f -
+          kubectl -n "$APP_NS" rollout restart deployment/airgapped-demo-backend deployment/airgapped-demo-frontend
+          kubectl -n "$APP_NS" rollout status deployment/airgapped-demo-backend --timeout=120s
+          kubectl -n "$APP_NS" rollout status deployment/airgapped-demo-frontend --timeout=120s
+
+      # ── Verify: confirm the running image matches what was just deployed ──────
+      - name: Post-deploy verification
+        env:
+          KUBECONFIG_B64: ${{ secrets.KUBECONFIG_B64 }}
+          EXPECTED_TAG: ${{ steps.tag.outputs.value }}
+        run: |
+          export KUBECONFIG=/tmp/kubeconfig
+          echo "### Post-deploy verification" >> $GITHUB_STEP_SUMMARY
+          echo '```' >> $GITHUB_STEP_SUMMARY
+          kubectl -n airgapped-demo get deployments \
+            -o custom-columns='NAME:.metadata.name,IMAGE:.spec.template.spec.containers[0].image,READY:.status.readyReplicas' \
+            >> $GITHUB_STEP_SUMMARY
+          echo '```' >> $GITHUB_STEP_SUMMARY
+
+          # Assert both deployments are running the expected tag
+          BACKEND_TAG=$(kubectl -n airgapped-demo get deployment airgapped-demo-backend \
+            -o jsonpath='{.spec.template.spec.containers[0].image}' | grep -o 'sha-[a-f0-9]*$')
+          FRONTEND_TAG=$(kubectl -n airgapped-demo get deployment airgapped-demo-frontend \
+            -o jsonpath='{.spec.template.spec.containers[0].image}' | grep -o 'sha-[a-f0-9]*$')
+
+          echo "Expected tag : $EXPECTED_TAG"
+          echo "Backend  tag : $BACKEND_TAG"
+          echo "Frontend tag : $FRONTEND_TAG"
+
+          [ "$BACKEND_TAG"  = "$EXPECTED_TAG" ] || { echo "FAIL: backend tag mismatch";  exit 1; }
+          [ "$FRONTEND_TAG" = "$EXPECTED_TAG" ] || { echo "FAIL: frontend tag mismatch"; exit 1; }
+          echo "✓ Both deployments are running $EXPECTED_TAG"
diff --git a/README.md b/README.md
@@ -0,0 +1,88 @@
+# airgapped-demo
+
+A full-stack demo application (React frontend + Express backend) designed to be packaged and deployed on air-gapped Kubernetes clusters using [Zarf](https://docs.zarf.dev).
+
+The repository covers the complete lifecycle: local development, container image publishing to AWS ECR, Zarf packaging in CI, and deployment to a k3s cluster with no external connectivity required at deploy time.
+
+---
+
+## Project Structure
+
+```
+├── backend/              Express.js REST API
+├── frontend/             React (Vite) single-page app
+├── helm/airgapped-demo/  Helm chart (deployed by Zarf)
+├── terraform/            AWS infrastructure (ECR, IAM, OIDC)
+├── .github/workflows/    CI/CD pipelines
+├── zarf.yaml             Zarf package definition
+├── Makefile              Local development targets
+├── ZARF.md               Air-gap packaging & deployment guide
+├── CI.md                 CI/CD pipeline reference
+└── SETUP.md              Initial infrastructure setup guide
+```
+
+---
+
+## Quick Start
+
+### Local (Docker Compose)
+
+```bash
+docker compose up
+# Frontend: http://localhost:5173
+# Backend:  http://localhost:3001/api/health
+```
+
+### Local Air-Gap (k3s via Zarf)
+
+```bash
+make registry        # start local Docker registry on localhost:5001
+make package-local   # build images → push → create Zarf tarball
+make deploy          # deploy to k3s cluster + post-deploy fixes
+```
+
+See [ZARF.md](ZARF.md) for the complete local and USB air-gap workflow.
+
+---
+
+## CI/CD Pipeline
+
+| Workflow | Trigger | What it does |
+|---|---|---|
+| **Build & Push Images** | push to `main` | Builds frontend + backend images, pushes to ECR with tag `sha-<7char>` |
+| **Zarf Package** | after Build & Push succeeds | Creates a `.tar.zst` bundle with images + Helm chart; uploads as a GitHub Actions artifact |
+| **Deploy** | after Zarf Package succeeds | Downloads the bundle, deploys to the k3s cluster, verifies running tags match |
+
+See [CI.md](CI.md) for secrets, permissions, and pipeline details.
+
+---
+
+## API Endpoints
+
+| Method | Path | Description |
+|---|---|---|
+| `GET` | `/api/health` | Health check — returns status, version, timestamp |
+| `GET` | `/api/info` | Runtime info — app name, version, hostname, environment |
+| `GET` | `/api/items` | Sample item list |
+
+---
+
+## AWS Infrastructure
+
+Managed with Terraform in `terraform/`. Resources:
+
+| Resource | Purpose |
+|---|---|
+| ECR repositories | `airgapped-demo/backend`, `airgapped-demo/frontend` |
+| IAM OIDC provider | Federated identity for GitHub Actions |
+| IAM roles | `cicd` (push images, no long-lived credentials) |
+
+See [SETUP.md](SETUP.md) for provisioning steps.
+
+---
+
+## Air-Gap Delivery
+
+The Zarf bundle (~66 MB) is self-contained — it embeds the container images and the Helm chart. The target cluster requires no internet access or ECR credentials at deploy time.
+
+For offline delivery to a machine with no internet access, see [ZARF.md § Air-Gap USB Deployment](ZARF.md#air-gap-usb-deployment).