CASAN/.gitea/vault-setup-runbook.md

HashiCorp Vault Setup — CASAN H5 KMS

Oracle Cloud VPS: 161.33.139.73

What this achieves

Before: private key = file on disk, verify-audit-chain → anchor=unsigned in CI After: private key = Vault Transit (never leaves Vault), CI → anchor=signed

---

Step 1 — Add Vault to /opt/gitea/docker-compose.yml

Add the vault service and a named volume. The key sections to add:

# ── Add to the top-level volumes section ─────────────────────────
volumes:
  gitea-data:
  act-runner-data:
  vault-data:           # ← ADD THIS

# ── Add the vault service ─────────────────────────────────────────
  vault:
    image: hashicorp/vault:latest
    container_name: vault
    restart: unless-stopped
    networks:
      - gitea
    ports:
      - "8200:8200"        # expose so you can init from outside
    environment:
      # Dev mode: auto-init, auto-unseal, in-memory storage.
      # Root token is fixed — store it as a Gitea secret after setup.
      VAULT_DEV_ROOT_TOKEN_ID: "${VAULT_ROOT_TOKEN}"
      VAULT_DEV_LISTEN_ADDRESS: "0.0.0.0:8200"
      VAULT_LOG_LEVEL: "warn"
    cap_add:
      - IPC_LOCK           # required by Vault
    command: server -dev

Dev mode stores keys in RAM — keys survive container restarts because the token and key name are fixed, and Vault re-creates them on each start. For production: switch to server mode with file storage backend.

---

Step 2 — Add VAULT_ROOT_TOKEN to /opt/gitea/.env

# Pick a strong token (or generate one)
echo "VAULT_ROOT_TOKEN=casan-vault-$(openssl rand -hex 16)" >> /opt/gitea/.env

# Verify
grep VAULT_ROOT_TOKEN /opt/gitea/.env

Save this token — you'll need it for the Gitea secret in Step 5.

---

Step 3 — Start Vault

cd /opt/gitea
docker compose pull vault
docker compose up -d vault

# Wait ~5 seconds for Vault to boot, then check:
docker compose logs vault | tail -20
# Look for: "Development mode should NOT be used in production installations!"
# and: "Root Token: <your token>"

Verify from outside:

curl http://161.33.139.73:8200/v1/sys/health
# Expected: {"initialized":true,"sealed":false,...}

---

Step 4 — Enable Transit engine + create signing keys

Run these from anywhere that can reach port 8200. Replace <TOKEN> with your VAULT_ROOT_TOKEN value.

export VAULT_ADDR=http://161.33.139.73:8200
export VAULT_TOKEN=<TOKEN>

# Enable Transit secrets engine
curl -sf -X POST \
  -H "X-Vault-Token: $VAULT_TOKEN" \
  -H "Content-Type: application/json" \
  -d '{"type":"transit"}' \
  "$VAULT_ADDR/v1/sys/mounts/transit"

# Create RSA-2048 key for policy bundle signing
curl -sf -X POST \
  -H "X-Vault-Token: $VAULT_TOKEN" \
  -H "Content-Type: application/json" \
  -d '{"type":"rsa-2048","exportable":false}' \
  "$VAULT_ADDR/v1/transit/keys/casan-policy-key"

# Create RSA-2048 key for audit chain signing
curl -sf -X POST \
  -H "X-Vault-Token: $VAULT_TOKEN" \
  -H "Content-Type: application/json" \
  -d '{"type":"rsa-2048","exportable":false}' \
  "$VAULT_ADDR/v1/transit/keys/casan-audit-key"

echo "Vault Transit keys created."

Verify keys exist:

curl -sf -H "X-Vault-Token: $VAULT_TOKEN" \
  "$VAULT_ADDR/v1/transit/keys/casan-policy-key" | python3 -c "
import sys,json; d=json.load(sys.stdin)
print('key type:', d['data']['type'])
print('exportable:', d['data']['exportable'])
"
# Expected: key type: rsa-2048 / exportable: False

---

Step 5 — Add VAULT_TOKEN as Gitea Actions Secret

1. Open Gitea: http://161.33.139.73:3000
2. Go to your repo → Settings → Secrets → Actions
3. Add new secret:
   • Name: VAULT_TOKEN
   • Value: your VAULT_ROOT_TOKEN value
4. Save.

The CI workflow references ${{ secrets.VAULT_TOKEN }} — this injects the token into the security-gate job without exposing it in logs.

---

Step 6 — Test Vault signing locally (optional)

From macOS with the project checked out:

export VAULT_ADDR=http://161.33.139.73:8200
export VAULT_TOKEN=<TOKEN>

cd Output_CASAN5_REFINED  # repo root (app promoted from )

# Test sign-policy-bundle with Vault
bash packages/casan-harness/scripts/bash/sign-policy-bundle.sh sign
# Expected: POLICY_BUNDLE_SIGNED ... key_backend=vault-kms

# Test sign-audit-head
bash packages/casan-harness/scripts/bash/sign-audit-head.sh
# Expected: SIGN_AUDIT_HEAD_OK ... anchor=vault-kms

# Verify audit chain
bash packages/casan-harness/scripts/bash/verify-audit-chain.sh
# Expected: AUDIT_CHAIN_VALID anchor=signed

---

Step 7 — Push code to trigger CI with Vault

git add .gitea/ packages/casan-harness/scripts/bash/vault-kms.sh \
        packages/casan-harness/scripts/bash/sign-audit-head.sh \
        packages/casan-harness/scripts/bash/sign-policy-bundle.sh
git commit -m "feat(H5): Vault KMS for policy + audit chain signing"
git push gitea main

Watch the CI run: http://161.33.139.73:3000//casan5/actions

Expected security-gate job output:

VAULT_KMS_READY
...
SIGN_AUDIT_HEAD_OK head=<hash> anchor=vault-kms
POLICY_BUNDLE_SIGNED ... key_backend=vault-kms
AUDIT_CHAIN_VALID anchor=signed          ← changed from "unsigned"
...
== verdict: PASS=7 FAIL=0 SKIP=1 ==

---

Architecture summary

CI Job (act_runner container)
│
├── vault-kms.sh sign   ──── POST /v1/transit/sign/casan-audit-key ──► Vault container
│                                                                        (key never leaves)
├── vault-kms.sh pubkey ──── GET  /v1/transit/keys/casan-audit-key ──► export public key
│                                                                         as PEM for openssl verify
└── verify-audit-chain.sh ── openssl dgst -verify audit-public.pem
    → AUDIT_CHAIN_VALID anchor=signed  ✅

Private key:

• Stored only inside Vault's in-memory transit engine
• Never written to disk as .pem
• Never visible in CI logs
• Access gated by VAULT_TOKEN Gitea secret

---

RAM footprint on VPS (1 GB)

Service	Idle RAM
Gitea	~180 MB
act_runner	~50 MB
Vault	~60 MB
Total idle	~290 MB
During CI	+300 MB (job container)
Peak	~590 MB ✅

Vault in dev mode uses ~60 MB — well within the 1 GB budget.