---
title: "Fix: Docker buildx cache 400 error — migrated to local volume cache"
description: "Registry buildx cache caused 400 errors; permanent fix is local volume cache on the Gitea Actions runner."
type: troubleshooting
domain: development
tags: [troubleshooting, docker, gitea, ci]
---

# Fix: Docker buildx cache 400 error on CI builds

**Date:** 2026-03-23
**Severity:** Medium — blocks CI/CD Docker image builds, requires manual intervention to retrigger

## Problem

Gitea Actions Docker build workflow fails at the "exporting cache to registry" step with:

```
error writing layer blob: failed to copy: unexpected status from PUT request to
https://registry-1.docker.io/v2/.../blobs/uploads/...: 400 Bad request
```

The image never gets pushed to Docker Hub. Seen on both Paper Dynasty and Major Domo repos.

## Root Cause

Stale `buildx_buildkit_builder-*` containers accumulate on the Gitea Actions runner host. Each CI build creates a new buildx builder instance but doesn't always clean up. Over time, these stale builders corrupt the registry cache state, causing Docker Hub to reject cache export PUT requests with 400.

## Fix

Kill all stale buildx builder containers on the runner, then retrigger the build:

```bash
# Kill stale builders
ssh gitea "docker rm -f \$(docker ps -a --format '{{.Names}}' | grep buildx_buildkit_builder)"

# Retrigger by deleting and re-pushing the tag
git push origin :refs/tags/<tag> && git push origin <tag>
```

## Lessons

- `type=registry` cache is unreliable on a single-runner setup — stale builders accumulate and corrupt cache state
- Killing stale builders is a temporary fix only

---

## Permanent Fix: Local Volume Buildx Cache (2026-03-24)

**Severity:** N/A — preventive infrastructure change

**Problem:** The `type=registry` cache kept failing with 400 errors. Killing stale builders was a manual band-aid.

**Root Cause:** Each CI build creates a new buildx builder container. On a single persistent runner (`gitea/act_runner`, `--restart unless-stopped`), these accumulate and corrupt the Docker Hub registry cache.

**Fix:** Switched all workflows from `type=registry` to `type=local` backed by a named Docker volume.

### Setup (one-time, on gitea runner host)

```bash
# Create named volume
docker volume create pd-buildx-cache

# Update /etc/gitea/runner-config.yaml
#   valid_volumes:
#     - pd-buildx-cache

# Recreate runner container with new volume mount
docker run -d --name gitea-runner --restart unless-stopped \
  -v /etc/gitea/runner-config.yaml:/config.yaml:ro \
  -v /var/run/docker.sock:/var/run/docker.sock \
  -v gitea-runner-data:/data \
  -v pd-buildx-cache:/opt/buildx-cache \
  gitea/act_runner:latest
```

### Workflow changes

1. Add `container.volumes` to mount the named volume into job containers:
```yaml
jobs:
  build:
    runs-on: ubuntu-latest
    container:
      volumes:
        - pd-buildx-cache:/opt/buildx-cache
```

2. Replace cache directives (each repo uses its own subdirectory):
```yaml
cache-from: type=local,src=/opt/buildx-cache/<repo-name>
cache-to: type=local,dest=/opt/buildx-cache/<repo-name>-new,mode=max
```

3. Add cache rotation step (prevents unbounded growth):
```yaml
- name: Rotate cache
  run: |
    rm -rf /opt/buildx-cache/<repo-name>
    mv /opt/buildx-cache/<repo-name>-new /opt/buildx-cache/<repo-name>
```

### Key details

- `type=gha` does NOT work on Gitea act_runner (requires GitHub's cache service API)
- Named volumes (not bind mounts) are required because job containers are sibling containers spawned via Docker socket
- `mode=max` caches all intermediate layers, not just final — important for multi-stage builds
- First build after migration is cold; subsequent builds hit local cache
- Cache size is bounded by the rotation step (~200-600MB per repo)
- Applied to: Paper Dynasty database, Paper Dynasty discord. Major Domo repos still use registry cache (follow-up)

### Repos using local cache
| Repo | Cache subdirectory |
|---|---|
| paper-dynasty-database | `/opt/buildx-cache/pd-database` |
| paper-dynasty-discord | `/opt/buildx-cache/pd-discord` |
