fix(openbao): switch readinessProbe to HTTP /sys/health to unblock bootstrap

k8s/bases/infrastructure/controllers/openbao/helm-release.yaml

@@ -27,6 +27,26 @@ spec:
     server:
       enabled: true
       replicas: ${openbao_replicas:=1}
+      # The chart's default readinessProbe is `exec: bao status`, which
+      # returns exit code 2 on a sealed server -- so the Pod stays NotReady
+      # until something unseals it. On a fresh cluster that "something" is
+      # the vault-config Job in the downstream `infrastructure` Flux layer,
+      # which can't run until this HelmRelease (in `infrastructure-controllers`)
+      # is Ready. The install therefore deadlocks: Helm waits up to `timeout`,
+      # `install.remediation.retries: -1` uninstalls + reinstalls, repeat --
+      # cold-cluster bootstrap historically took 20-40 min waiting for that
+      # race to resolve (see vault-config Job comment + PR #1636 system-test
+      # failure).
+      #
+      # Switching to the HTTP health probe with `sealedcode=204` and
+      # `uninitcode=204` makes a sealed-but-running server Ready immediately.
+      # The chart template renders the httpGet branch as soon as `path` is
+      # set (server-statefulset.yaml: `{{- if .Values.server.readinessProbe.path }}`)
+      # and `openbao.scheme` returns "http" when `global.tlsDisable: true`
+      # (chart default; matches the `tls_disable = 1` listener below).
+      # The HashiCorp Vault chart uses the same pattern for the same reason.
+      readinessProbe:
+        path: "/v1/sys/health?standbyok=true&sealedcode=204&uninitcode=204"
       # Mount the unseal key Secret (created by the vault-config Job on first
       # init, restored by Velero on cluster rebuild) so the postStart hook
       # can auto-unseal the server after every pod restart.