fix(hostedclustersizing): add override fall back

[SudoBrendan]

What this PR does / why we need it:

Today, if you set the size override annotation, but that size isn't an exact string match of what's in the config, your cluster will remain unsized rather than falling back to the standard logic (autoscale / node size). The only indication this has happened is a log message in the controller.

NOTE: I think this seems odd - do others agree this is a bug, not a feature? Is there a reason to prefer an unsized cluster when the override is set incorrectly that I'm unaware of?

Which issue(s) this PR fixes:

Adjacent work I happened to discover while trying to refine what CNTRLPLANE-2581 would be

Special notes for your reviewer:

Checklist:

• Subject and description added to both, commit and PR.
• Relevant issues have been referenced.
• This change includes docs.
• This change includes unit tests.

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PR needs rebase.

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[hypershift-jira-solve-ci]

I now have all the evidence to produce the report. Let me compile the final analysis.

Test Failure Analysis Complete

Job Information

• Prow Job: tide (merge automation)
• Build ID: N/A (tide is a merge-status controller, not a CI job run)
• PR: #7554 — fix(hostedclustersizing): add override fall back
• Branch: sudobrendan/fix-size-override-fallback
• Head SHA: 84e7bb0e83f3e5e8dfbb5009833a98a4a1875296
• Author: SudoBrendan

Test Failure Analysis

Error

tide: Not mergeable. PR has a merge conflict.

Summary

The tide error is not a test failure — it is a merge-conflict blocker. PR #7554 was created on 2026-01-20 and has never been rebased. The branch is now 1,350 commits behind main and has merge conflicts in both files it touches (hostedclustersizing_controller.go and hostedclustersizing_controller_test.go). The direct cause of the conflict is PR #8309 ("Enable gocyclo linter and reduce cyclomatic complexity"), merged 2026-05-07, which refactored the same hostedclustersizing_controller.go file with 370 changed lines (224 additions, 146 deletions) — extracting helper functions and restructuring the code that PR #7554 also modifies. Additionally, 3 Konflux Enterprise Contract checks fail because the branch carries stale .tekton/ pipeline task bundle digests from before PR #8048 (merged 2026-03-23). All actual Prow CI jobs (e2e-azure-self-managed, security, unit, verify-workflows) passed. The PR is also still in Draft state with do-not-merge/work-in-progress and needs-rebase labels.

Root Cause

Merge conflict due to a 4-month-old un-rebased branch, with conflicting refactors on main.

The PR modifies hostedclustersizing_controller.go (lines ~208–260) to change the sizing priority logic — making override annotation fall back gracefully to autoscaling or node-count sizing instead of silently ignoring invalid overrides. Since the PR was created on 2026-01-20, two commits on main modified the same file:

1. PR #8309 (merged 2026-05-07) — Major refactor of hostedclustersizing_controller.go to reduce cyclomatic complexity. This commit changed 370 lines in the controller (224 additions, 146 deletions) and 613 lines in the test file. It extracted helper functions and restructured the reconcile() method — the exact same function PR fix(hostedclustersizing): add override fall back #7554 modifies. This is the primary source of the merge conflict.

2. PR with commit aee93fe8e865 (merged 2026-04-16) — Lint fix that renamed unused parameters to _ in the same file. Minor (2-line change) but contributes to the divergence.

The branch is 1,350 commits behind main (status: diverged, ahead by 1, behind by 1,350), making GitHub report the PR as CONFLICTING with mergeStateStatus: DIRTY.

Secondary issue — Konflux Enterprise Contract failures (3 checks):
The .tekton/ pipeline YAML files on the branch reference Tekton task bundle digests that have been rotated out of the trusted catalog since PR #8048 updated them on 2026-03-23. This causes trusted_task.trusted policy violations in all Enterprise Contract validation checks. This is a staleness issue, not a code problem.

Importantly: All actual CI test jobs passed — e2e-azure-self-managed (success), security (success), unit (success, context retired), verify-workflows (success, context retired). The code change itself is not causing any test failures.

Recommendations

1. Rebase onto main — This is the only action needed to resolve both the tide merge conflict and the Konflux Enterprise Contract failures:

   git fetch origin main
   git rebase origin/main
   # Resolve conflicts in hostedclustersizing_controller.go and _test.go
   # The refactor in PR #8309 restructured the reconcile() method —
   # re-apply the override-fallback logic on top of the new structure
   git push --force-with-lease

2. Expect non-trivial conflict resolution — PR CNTRLPLANE-3324: Enable gocyclo linter and reduce cyclomatic complexity #8309's refactor extracted helper functions from the reconcile() method. The sizing-priority changes from this PR will need to be re-applied to the new code structure. Review the current main version of hostedclustersizing_controller.go carefully before resolving.

3. Mark PR as ready for review — The PR is currently in Draft state with do-not-merge/work-in-progress label. After rebasing, convert it from draft and remove the WIP label to allow tide to consider it for merging.

4. Re-trigger required CI jobs after rebase — the unit and verify-workflows contexts show as "retired without replacement", so verify which required checks are currently configured for the repo.

Evidence

Evidence	Detail
Tide error	"Not mergeable. PR has a merge conflict." (state: ERROR, 2026-05-11T23:24:32Z)
PR age	Created 2026-01-20, last commit 2026-01-20 — ~4 months without rebase
Branch divergence	1,350 commits behind main, 1 ahead (status: diverged)
GitHub merge state	mergeable: CONFLICTING, mergeStateStatus: DIRTY
Conflicting file	hostedclustersizing_controller.go — modified by both PR #7554 and PR #8309
Primary conflict source	PR #8309 (merged 2026-05-07): gocyclo refactor, 370 changed lines in controller, 613 in test file
Secondary conflict source	Commit aee93fe8e865 (merged 2026-04-16): unparam lint fix, 2-line change
PR labels	needs-rebase, do-not-merge/work-in-progress, area/hypershift-operator
PR state	Draft (isDraft: true)
Konflux EC failures	3 checks fail due to stale .tekton/ task bundle digests (rotated since PR #8048, merged 2026-03-23)
Passing CI jobs	e2e-azure-self-managed ✅, security ✅, unit ✅ (retired), verify-workflows ✅ (retired)
Code changes (PR #7554)	2 Go files only: sizing controller + tests — unrelated to CI/pipeline config

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