Bootstrap for UPI Bare Metal never complete when attempting to define a disk parition for /var

[xinkecf35]

Describe the bug

When attempting to follow instructions to create a dedicated /var partition as recommended for large boot disk, i.e. 1TB, the bootstrap never completes. It only gets as far as rebooting the non-rendevzous control-plane machine to wait for them to join, but they never do and thus it just hangs.

Inspecting the machine-config-server endpoint, I get a 500 error

❯ curl -kv -o /dev/null https://api-int.lab-01.okd.home.arpa:22623/config/master
  % Total    % Received % Xferd  Average Speed   Time    Time     Time  Current
                                 Dload  Upload   Total   Spent    Left  Speed
  0     0    0     0    0     0      0      0 --:--:-- --:--:-- --:--:--     0* Host api-int.lab-01.okd.home.arpa:22623 was resolved.
* IPv6: (none)
* IPv4: 192.168.2.18
*   Trying 192.168.2.18:22623...
* Connected to api-int.lab-01.okd.home.arpa (192.168.2.18) port 22623
* ALPN: curl offers h2,http/1.1
* (304) (OUT), TLS handshake, Client hello (1):
} [333 bytes data]
* (304) (IN), TLS handshake, Server hello (2):
{ [122 bytes data]
* (304) (IN), TLS handshake, Unknown (8):
{ [21 bytes data]
* (304) (IN), TLS handshake, Certificate (11):
{ [880 bytes data]
* (304) (IN), TLS handshake, CERT verify (15):
{ [264 bytes data]
* (304) (IN), TLS handshake, Finished (20):
{ [36 bytes data]
* (304) (OUT), TLS handshake, Finished (20):
} [36 bytes data]
* SSL connection using TLSv1.3 / AEAD-CHACHA20-POLY1305-SHA256 / [blank] / UNDEF
* ALPN: server accepted http/1.1
* Server certificate:
*  subject: CN=system:machine-config-server
*  start date: Apr  6 00:44:40 2025 GMT
*  expire date: Apr  4 00:44:40 2035 GMT
*  issuer: OU=openshift; CN=root-ca
*  SSL certificate verify result: unable to get local issuer certificate (20), continuing anyway.
* using HTTP/1.x
> GET /config/master HTTP/1.1
> Host: api-int.lab-01.okd.home.arpa:22623
> User-Agent: curl/8.7.1
> Accept: */*
> 
* Request completely sent off
< HTTP/1.1 500 Internal Server Error
< Content-Length: 0
< Date: Sun, 06 Apr 2025 01:46:48 GMT
< 
  0     0    0     0    0     0      0      0 --:--:-- --:--:-- --:--:--     0
* Connection #0 to host api-int.lab-01.okd.home.arpa left intact

Inspecting the pod, I get a similar error as seen with #2041:

E0406 00:58:13.543238       1 api.go:209] couldn't convert config for req: {master 0xc000a8d1c0}, error: failed to convert config from spec v3.5 to v2.2: unable to convert Ignition spec v3 config to v2: SizeMiB and StartMiB in Storage.Disks.Partitions is not supported on 2.2

Only difference is I don't believe I see the issues described since I don't have a RAID setup involved, just an additional disk partition on the filesystem.

For reference, here's the Butane and generated MC

disk-parition-butane-ignition.zip

Version

4.19.0-okd-scos.ec.7

UPI - Bare Metal - Agent Based Install

How reproducible

Every time I try to boot with this configuration.

Log bundle

log-bundle-20250405213331.tar.gz