fix(delivery): derive installation reserve from verified inventory

deploy/release/README.md

@@ -10,6 +10,10 @@ The target has at least 4 GiB RAM and 12 GiB installation/data capacity. Judging
 and problem-import concurrency remain one each. Configured service and execution
 budgets, effective kernel limits and free capacity must also pass preflight; total
 RAM alone does not prove enough capacity or verified execution isolation.
+Preflight requires at least 12 GiB of filesystem capacity and derives required
+free bytes from the verified application, protected runtime-image copies and
+separate GNU legacy copy, plus 4 GiB of mutable-data/operation reserve. It does
+not assume that a nominal 12-GiB filesystem exposes 12 GiB free after metadata.
 
 Release payloads are directory bundles with a bounded manifest: at most 50,000
 single-link regular files, 256 MiB per file, 4 GiB total and 8 MiB metadata. The

scripts/release/__main__.py

@@ -61,8 +61,8 @@ def main() -> None:
         elif args.command == "build":
             result = build.build(args.repo, args.inputs, args.output, args.work)
         elif args.command == "preflight":
-            manifest.verify(args.bundle, args.manifest_sha256)
-            result = preflight.observe(args.bundle / "payload")
+            data = manifest.verify(args.bundle, args.manifest_sha256)
+            result = preflight.observe(args.bundle / "payload", bundle_data=data)
             print(json.dumps(result, sort_keys=True))
             if not result["eligible"]:
                 parser.exit(1)

scripts/release/install.py

@@ -182,7 +182,7 @@ def files(bundle: Path, expected: str) -> dict:
         raise DeliveryError("installer requires root")
     preflight.protected(bundle, directory=True)
     data = manifest.verify(bundle, expected)
-    observation = preflight.observe(bundle / "payload")
+    observation = preflight.observe(bundle / "payload", bundle_data=data)
     if not observation["eligible"]:
         raise DeliveryError("installation preflight refused: " + "; ".join(observation["errors"]))
     # Per-entry ownership matters even when the inventory is identical.

scripts/release/preflight.py

@@ -120,7 +120,7 @@ def identity_conflicts() -> list[str]:
     return errors
 
 
-def observe(payload: Path, *, require_root: bool = True) -> dict:
+def observe(payload: Path, *, bundle_data: dict, require_root: bool = True) -> dict:
     errors = []
     observations = {}
     if platform.system() != "Linux" or platform.machine() != "x86_64":
@@ -183,9 +183,24 @@ def observe(payload: Path, *, require_root: bool = True) -> dict:
     # A 4-GiB physical guest exposes slightly less MemTotal after kernel reserve.
     if memory["MemTotal"] < 15 * GIB // 4 or memory["MemAvailable"] < 5 * GIB // 2:
         errors.append("physical/available memory below installation capacity")
-    observations["disk_free_bytes"] = shutil.disk_usage("/var/lib").free
-    if observations["disk_free_bytes"] < 12 * GIB:
-        errors.append("installation/data disk reserve below 12 GiB")
+    disk = shutil.disk_usage("/var/lib")
+    protected_images = sum(
+        entry["bytes"] for entry in bundle_data["files"] if entry["path"].startswith("images/")
+    )
+    legacy_image = sum(
+        entry["bytes"] for entry in bundle_data["files"] if entry["path"].startswith("images/gnu/")
+    )
+    # Count a full new application + protected image copies + legacy image and
+    # four GiB of mutable data/operation reserve. Filesystem metadata makes a
+    # 12-GiB device expose less than 12 GiB free even when it is empty.
+    required = bundle_data["payload_bytes"] + protected_images + legacy_image + 4 * GIB
+    observations["disk"] = {
+        "total_bytes": disk.total,
+        "free_bytes": disk.free,
+        "required_free_bytes": required,
+    }
+    if disk.total < 12 * GIB or disk.free < required:
+        errors.append("installation/data capacity or inventory-derived free reserve insufficient")
     for name in ("libc.so.6", "ld-linux-x86-64.so.2"):
         system = Path("/usr/lib") / name
         try: