Merge pull request #151 from theta42/fix/auto-reset-unseal-key-loss-v1.35.8

fix(setup): auto-reset OpenBao volume and re-initialize if unseal key is lost v1.35.8

setup.sh

@@ -106,6 +106,13 @@ env_upsert() {
 	fi
 }
 
+# Read KEY= from ./.env (empty if absent)
+env_get() {
+	local key="$1" file=./.env
+	[[ -f "$file" ]] || return 0
+	grep -m1 "^${key}=" "$file" 2>/dev/null | cut -d= -f2- || true
+}
+
 # Detect docker compose (v2 plugin `docker compose` or v1 standalone `docker-compose`).
 if docker compose version >/dev/null 2>&1; then
 	COMPOSE=(docker compose)
@@ -676,6 +683,16 @@ for i in $(seq 1 30); do
 	sleep 2
 done
 
+# If config/bao-init.json is missing, search backups for a saved copy
+if [[ ! -f "$CONFIG_DIR/bao-init.json" ]]; then
+    latest_backup_init=$(find ./backups -name "bao-init.json" 2>/dev/null | sort -r | head -n1 || true)
+    if [[ -n "$latest_backup_init" && -f "$latest_backup_init" ]]; then
+        info "Restoring $CONFIG_DIR/bao-init.json from backup ($latest_backup_init)..."
+        cp "$latest_backup_init" "$CONFIG_DIR/bao-init.json"
+        chmod 600 "$CONFIG_DIR/bao-init.json"
+    fi
+fi
+
 if ! docker exec openbao bao status -format=json 2>/dev/null | grep -q '"initialized": true'; then
     status_json=$(docker exec openbao bao status -format=json 2>/dev/null || true)
     if ! echo "$status_json" | grep -q '"initialized": true'; then
@@ -688,13 +705,52 @@ fi
 
 status_json=$(docker exec openbao bao status -format=json 2>/dev/null || true)
 if echo "$status_json" | grep -q '"sealed": true'; then
-	info "Unsealing openbao..."
-	UNSEAL_KEY=$(grep -A1 '"unseal_keys_b64":' "$CONFIG_DIR/bao-init.json" | tail -n1 | cut -d'"' -f2)
-	docker exec openbao bao operator unseal "$UNSEAL_KEY" >/dev/null
+	UNSEAL_KEY=""
+	if [[ -f "$CONFIG_DIR/bao-init.json" ]]; then
+		UNSEAL_KEY=$(grep -A1 '"unseal_keys_b64":' "$CONFIG_DIR/bao-init.json" 2>/dev/null | tail -n1 | cut -d'"' -f2 || true)
+	fi
+	if [[ -z "$UNSEAL_KEY" ]]; then
+		UNSEAL_KEY="$(env_get VAULT_UNSEAL_KEY)"
+	fi
+
+	if [[ -n "$UNSEAL_KEY" ]]; then
+		info "Unsealing openbao..."
+		docker exec openbao bao operator unseal "$UNSEAL_KEY" >/dev/null
+	else
+		warn "OpenBao is sealed with an unrecoverable key. Resetting OpenBao volume and re-initializing..."
+		"${COMPOSE[@]}" stop openbao >/dev/null 2>&1 || true
+		"${COMPOSE[@]}" rm -f openbao >/dev/null 2>&1 || true
+		docker volume ls -q 2>/dev/null | grep openbao | xargs -r docker volume rm >/dev/null 2>&1 || true
+		"${COMPOSE[@]}" up -d openbao >/dev/null 2>&1 || true
+		info "Waiting for fresh openbao container..."
+		for i in $(seq 1 30); do
+			if docker exec openbao bao status >/dev/null 2>&1 || [[ $? -eq 2 ]]; then break; fi
+			sleep 2
+		done
+		info "Initializing fresh openbao..."
+		docker exec openbao bao operator init -key-shares=1 -key-threshold=1 -format=json > "$CONFIG_DIR/bao-init.json"
+		chmod 600 "$CONFIG_DIR/bao-init.json"
+		UNSEAL_KEY=$(grep -A1 '"unseal_keys_b64":' "$CONFIG_DIR/bao-init.json" | tail -n1 | cut -d'"' -f2)
+		info "Unsealing fresh openbao..."
+		docker exec openbao bao operator unseal "$UNSEAL_KEY" >/dev/null
+	fi
 fi
 
 export VAULT_TOKEN
-VAULT_TOKEN=$(grep '"root_token":' "$CONFIG_DIR/bao-init.json" | cut -d'"' -f4)
+if [[ -f "$CONFIG_DIR/bao-init.json" ]]; then
+	VAULT_TOKEN=$(grep '"root_token":' "$CONFIG_DIR/bao-init.json" 2>/dev/null | cut -d'"' -f4 || true)
+fi
+if [[ -z "$VAULT_TOKEN" ]]; then
+	VAULT_TOKEN="$(env_get VAULT_TOKEN)"
+fi
+
+if [[ -z "$VAULT_TOKEN" ]]; then
+	die "Could not determine OpenBao VAULT_TOKEN from $CONFIG_DIR/bao-init.json or .env."
+fi
+
+if [[ -n "$UNSEAL_KEY" ]]; then
+	env_upsert VAULT_UNSEAL_KEY "$UNSEAL_KEY"
+fi
 env_upsert VAULT_TOKEN "$VAULT_TOKEN"
 
 if ! docker exec -e BAO_TOKEN="$VAULT_TOKEN" openbao bao secrets list -format=json 2>/dev/null | grep -q '"secret/":'; then
@@ -724,21 +780,6 @@ ensure_policy() {
 	docker exec -i -e BAO_TOKEN="$VAULT_TOKEN" openbao bao policy write "$name" - >/dev/null
 }
 
-# Read KEY= from ./.env (empty if absent) — reuse a previously minted token
-# instead of minting a fresh one on every setup.sh run.
-env_get() {
-	local key="$1" file=./.env
-	[[ -f "$file" ]] || return 0
-	# `|| true` is load-bearing: under `set -euo pipefail`, a no-match `grep`
-	# exits 1 and (pipefail) makes the whole pipeline return 1. Callers do
-	# `existing="$(env_get ...)"` as a bare assignment — a non-zero return there
-	# trips `set -e` and silently kills the whole script (this is exactly what
-	# aborted a fresh install right after "Minting per-app OpenBao tokens": the
-	# root VAULT_TOKEN env_upsert had already created .env, but the app-token
-	# keys were absent, so the first env_get returned 1). "Key absent" is the
-	# normal path here, so always return 0 with empty output.
-	grep -m1 "^${key}=" "$file" 2>/dev/null | cut -d= -f2- || true
-}
 
 # Mint an orphan, renewable token for `policy` and persist it to .env as `key`,
 # OR reuse the token already in .env if it is still valid (re-mint on expiry).