Create Empty /var/configs dir

[HMetcalfeW]

Description

Issue identified when testing the addition of GZIP Azure billing exports. The default option is to download exports to file vs. streaming them.

Also fixed two minor issues where empty manifests are generated because the --- break between manifests wasn't included within the if blocks.

Example error

ERR CloudCost[37be364a-7abe-43b0-8733-187289efe4e3/all-data-export/kubecost/hunter-zip-test-amortized-cost]: ingestor: build failed for window [2026-01-20T00:00:00+0000, 2026-01-21T00:00:00+0000): CloudCost: Azure: DownloadBlobToFile: failed to create directory mkdir /var/configs/db: permission denied

Related Issues

Relates to opencost/opencost#3572

User Impact

Without the env variable AZURE_DOWNLOAD_BILLING_DATA_TO_DISK set to false, cloud-costs will not work.

opencost:
env:
- name: AZURE_DOWNLOAD_BILLING_DATA_TO_DISK
value: "false"

Testing

See testing steps as part of: opencost/opencost#3572

Tested with these Helm values

opencost:
  # Cloud integration secret containing cloud-integration.json
  cloudIntegrationSecret: "cloud-integration"
  cloudCost:
    enabled: true
  
  exporter:
    image:
      registry: docker.io
      repository: huntermetcalfe/opencost
      tag: latest
      pullPolicy: Always/export"
    
    # Default cluster ID
    defaultClusterId: "azure-test-cluster"

Current develop branch with values above

helm upgrade --install opencost opencost-charts/opencost \
    --namespace opencost \
    --values values-azure.yaml

Deployed with modified Helm Chart

helm upgrade --install opencost ~/projects/HMetcalfe/opencost-helm-chart/charts/opencost \
    --namespace opencost \
    --values values-azure.yaml

[Copilot]

Pull request overview

This PR addresses permission issues when downloading Azure billing exports to disk by creating an empty /var/configs directory mount. It also fixes a Helm template bug where empty manifest separators were being generated when certain features were disabled.

Changes:

• Added emptyDir volume mount for /var/configs directory to fix permission denied errors when downloading Azure billing data
• Fixed manifest separator placement in ingress and httproute templates to prevent empty manifest generation

Reviewed changes

Copilot reviewed 3 out of 3 changed files in this pull request and generated no comments.

File	Description
charts/opencost/templates/deployment.yaml	Added var-configs emptyDir volume and mount to create the /var/configs directory before mounting cloud integration files
charts/opencost/templates/ingress.yaml	Moved --- manifest separators inside conditional blocks to prevent empty manifest output when features are disabled
charts/opencost/templates/httproute.yaml	Moved --- manifest separators inside conditional blocks to prevent empty manifest output when features are disabled

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[ameijer]

bump the chart version please

[ameijer]

@HMetcalfeW looks good to us, can you bump chart version?

[ameijer]

@HMetcalfeW can you bump the chart? then ping ishaan and we will get this merged!

[HMetcalfeW]

@ameijer, I've fixed the merge conflicts and have bumped the Helm Chart version

[Copilot]

Pull request overview

Copilot reviewed 4 out of 4 changed files in this pull request and generated 4 comments.

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