Aleksei Sviridkin 22ce998890 fix(flux-shard-operator): repair sharded helm-controller crashloop behind an HTTP proxy (#3546)
## What this PR does

Fixes #3544.

`flux-shard-operator` clones the flux-aio `helm-controller` container
into each `helm-controller-shard<i>` Deployment. It already sanitises
the all-in-one localhost wiring, but keeps two things that stop the
standalone shard from starting behind a corporate HTTP proxy:

1. **Inherited `HTTP_PROXY`/`HTTPS_PROXY`/`NO_PROXY`.** A standalone
shard needs no external egress (source-controller fetches artifacts).
Behind an unreachable proxy the controller makes a blocking startup
HTTPS call that never completes, the manager never serves `/healthz`,
and the liveness probe crashloops the pod forever. flux-aio survives
only because it starts once and never restarts. On an affected cluster
every HelmRelease carrying a `sharding.fluxcd.io/key` (150 of ~240) was
frozen for days, silently.

2. **No `startupProbe`.** The clone inherits only a ~30s liveness
window, so any slow start (large cache sync) is fatal and unrecoverable.

This PR extends the sanitisation to drop the proxy env, and derives a
`startupProbe` from the liveness handler with a generous budget so a
slow-but-progressing start is not killed. Verified by an A/B on a live
cluster (throwaway helm-controller with a non-matching selector): with
the proxy env it hangs; without it, it starts cleanly (`Starting
workers`).

### Downstream repositories
- [x] No downstream repository is affected by this change

Internal operator behavior only; no API/CRD/values contract change.

### Release note
```release-note
fix(flux-shard-operator): sharded helm-controller no longer crashloops at startup behind an HTTP proxy; the cloned controller drops the inherited proxy env and gains a startupProbe, so HelmReleases assigned to shards keep reconciling in proxied environments.
```


<!-- This is an auto-generated comment: release notes by coderabbit.ai
-->
## Summary by CodeRabbit

* **Bug Fixes**
* Prevented inherited proxy settings, including uppercase and lowercase
variants of `NO_PROXY`, from affecting Flux shard deployments.
* Automatically adds a startup health check when only a liveness check
is configured.
* Preserved the liveness check’s handler and timeout while applying
appropriate startup timing and failure settings.

* **Documentation**
  * Documented startup health checks for slow helm-controller startup.
<!-- end of auto-generated comment: release notes by coderabbit.ai -->
2026-08-14 13:28:51 +03:00
2025-10-08 09:43:34 +05:00
2025-04-01 18:48:14 +02:00
2024-02-08 12:04:32 +01:00

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