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Check out Talos Linux , it essentially solves a lot of the OS level challenges because there is no hardening requirements, the whole OS is API driven and you can bootstrap a cluster using their CLI. The entire node config is basically just a YAML file so can be managed via a GitOps workflow, then you can just layer something like Flux or Argo on top.
There is a tool written for this exact scenario! (disclaimer: I am a maintainer) https://github.com/defenseunicorns/zarf . Zarf can create packages out of all of your images, Helm charts, manifests... and deploy that package w/ zero dependencies on the other side (you can even use k3s built into the default init package if you don't have a cluster). The docs do it more justice https://docs.zarf.dev/docs/zarf-overview .
We have on premise clusters built that only have access to internal sites, no access to the internet. We've done this with 2 versions of K8s. The first we used a tool that was created in house. The guy who built it put it up on GitHub. It is the imageswap web hook. I haven't kept up with it since we've stopped using it, but it used to take everything other than the image name and tag and swap it with whatever we set. So, something like "webdevops/toolbox:latest" would be changed to "registry.internal.org/images/toolbox:latest" if we set our registry and path to "registry.internal.org/images". Then we'd just stage all of the necessary images in that image registry. You could choose which namespaces to label to use the image swap and which to leave alone.
Wow, thanks! Yes, we created & maintain the kurl.sh project that OP mentioned (disclaimer: I work there). Our customers (HashiCorp, BigID, Smartbear etc) basically get all the tooling to do all of the commercial things the OP mentioned (combining it with Helm or KOTS our installer, Troubleshoot.sh for disconnected troubleshooting etc).
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