Fix corrupted splunk-operator-3.0.0.tgz causing Helm test failures

[gabrielm-splunk]

Problem

After merging PR #1832 to restore helm support for 3.0.0, helm-tests are failing with:

Error: INSTALLATION FAILED: template: splunk-enterprise/charts/splunk-enterprise/templates/enterprise_v4_ingestorcluster.yaml:1:14: 
executing "splunk-enterprise/charts/splunk-enterprise/templates/enterprise_v4_ingestorcluster.yaml" at <.Values.ingestorCluster.enabled>: 
nil pointer evaluating interface {}.enabled

Root Cause

The splunk-operator-3.0.0.tgz file was corrupted - it contained the full splunk-enterprise chart package (4.5MB) instead of just the splunk-operator chart (5.8KB). This caused Helm to load a stale splunk-enterprise as a subchart within the operator chart, leading to nested template path errors.

File size comparison:

• Corrupted: splunk-operator-3.0.0.tgz = 4.5MB (contains full splunk-enterprise chart)
• Correct: splunk-operator-3.0.0.tgz = 5.8KB (contains only operator chart)
• Reference: splunk-operator-3.1.0.tgz = 6.7KB (correct structure)

The corruption happened in multiple "Restore helm chart version 3.0.0 to repository index" commits (b9766dd and related).

Solution

1. Restored correct tgz file

• Extracted good version from git history (commit a3737ba)
• File now contains only splunk-operator chart content, not nested splunk-enterprise

2. Added validation tooling

Created tools/validate-helm-charts.sh to detect future corruption:

• ✅ Validates tgz starts with splunk-operator/ directory (not splunk-enterprise/)
• ✅ Checks for embedded splunk-enterprise/Chart.yaml content
• ✅ Verifies file sizes are reasonable for version (3.x ~5-10KB, 2.x ~400-430KB with CRDs)
• ✅ Detects files over 1MB (clear sign of full chart package)

3. Automated CI/CD validation

Created .github/workflows/validate-helm-charts.yml that runs on:

• PRs touching helm-chart files
• Pushes to main/develop
• Manual workflow dispatch

The workflow performs:

• Tgz structure validation - Runs tools/validate-helm-charts.sh on all operator chart tgz files
• Helm lint - Validates both splunk-operator and splunk-enterprise charts
• Template rendering tests - Tests default, c3, and s1 deployment patterns
• PR comments - Automatically comments on PRs if validation fails with helpful diagnostics

This CI check would have caught the corruption before it was merged to develop.

Testing

• ✅ helm lint passes on both splunk-operator and splunk-enterprise charts
• ✅ helm template successfully renders c3 deployment without nil pointer errors
• ✅ Validation script detects corruption when tested with intentionally bad file
• ✅ All operator chart tgz files validated successfully (2.3.0 - 3.1.0)
• ✅ Template rendering tests pass for default, c3, and s1 deployments

Verification Commands

# Validate all charts
./tools/validate-helm-charts.sh

# Test template rendering for c3 deployment
helm template test-c3 helm-chart/splunk-enterprise \
  --set sva.c3.enabled=true \
  --set "sva.c3.indexerClusters[0].name=idx1" \
  --set "sva.c3.searchHeadClusters[0].name=shc1" \
  --set clusterManager.enabled=true

# Lint charts
helm lint helm-chart/splunk-operator
helm lint helm-chart/splunk-enterprise

Files Changed

• helm-chart/splunk-enterprise/charts/splunk-operator-3.0.0.tgz - Restored correct 5.8KB version
• tools/validate-helm-charts.sh - Validation script for detecting tgz corruption
• .github/workflows/validate-helm-charts.yml - Automated CI/CD validation workflow

Related Issues

• PR Restore helm chart version 3.0.0 to repository index #1832 - Restored helm chart 3.0.0 but with corrupted tgz
• Helm test failures in c3-with-operator deployment

Fixes the helm test error reported after PR #1832 merge and adds safeguards to prevent future occurrences.