52-Node Bare-Metal Elasticsearch Cluster — Built in a Weekend

Lead Operations Engineer – DevOps · Network Redux

Designed and built one of the largest search indexing clusters for a global media intelligence company — 52 bare-metal nodes in Network Redux’s private cloud. Completed over a single weekend, in between flights from Portland to Kochi.

Context

A global media intelligence company needed a large-scale Elasticsearch cluster for search indexing, deployed on dedicated bare-metal infrastructure in a private cloud environment. The project required end-to-end delivery — from network architecture through OS provisioning to production handover — on an aggressive timeline.

What I Did

  • Designed a dedicated DMZ zone for the Elasticsearch environment within Juniper SRX firewall clusters
  • Configured Arista switches with VLANs for network segmentation and isolation
  • Deployed 52 bare-metal instances with CentOS, security hardening, and client-specific customizations
  • Implemented zero-touch OS installation using PXE boot for consistent, repeatable provisioning
  • Built Ansible playbooks for all OS-level configurations across all 52 nodes
  • Oversaw full documentation and structured handover to the operations team

Results

MetricDetail
Nodes deployed52 bare-metal instances
Delivery timeSingle weekend
ScaleOne of the largest search indexing clusters for the client
ProvisioningZero-touch — fully automated via PXE + Ansible

Stack

Elasticsearch · Bare Metal · CentOS · PXE Boot · Ansible · Juniper SRX · Arista Switches · Private Cloud