Self-hosted on Kubernetes: SMTP mailer sends EHLO [127.0.0.1], rejected by strict SMTP relays (all outbound email fails) #6778

Summary

On self-hosted Kubernetes deployments, the SMTP email provider sends EHLO [127.0.0.1] on every connection. Strict SMTP servers — notably Google Workspace's SMTP relay (smtp-relay.gmail.com) — reject this with a 421 tarpit, so every outbound email fails (invitations, verification, etc.) even when the relay is configured correctly.

Root cause

apps/sim/lib/messaging/email/providers/smtp.ts creates the nodemailer transport without a name option:

const transporter = nodemailer.createTransport({
  host: env.SMTP_HOST,
  port,
  secure,
  auth: ...,
})

When name is not provided, nodemailer's SMTPConnection._getHostname() falls back to os.hostname() — and if that hostname contains no dot, it replaces it with [127.0.0.1]:

_getHostname() {
  let hostname;
  try { hostname = os.hostname() || ''; } catch (err) { hostname = 'localhost'; }
  if (!hostname || hostname.indexOf('.') < 0) {
    hostname = '[127.0.0.1]';   // <-- always taken on Kubernetes
  }
  ...
}

Kubernetes pod hostnames (e.g. sim-app-5b8f7d9c4-x2k9q) never contain a dot, so on k8s this fallback is taken 100% of the time and the mailer introduces itself as loopback.

Symptom

Against Google Workspace SMTP relay, every send fails at the EHLO stage:

Error: Server terminates connection. response=421-4.7.0 Try again later, closing connection. (EHLO)
421-4.7.0  For more information, go to
421 4.7.0  https://support.google.com/a/answer/3221692 ... - gsmtp

surfaced in the UI as All email providers failed: ... (e.g. when inviting workspace members). Note: Sim still creates the invitation DB row before the email attempt, so the UI can show a member as invited even though no email was ever delivered.

This is easy to misdiagnose as a relay/allowlist misconfiguration — the relay setup was correct in our case, and raw SMTP sessions from the same pod / same egress IP succeeded whenever a dotted EHLO name was used.

Reproduction

From any Kubernetes pod, open an SMTP session to smtp-relay.gmail.com:587:

• EHLO [127.0.0.1] → 421-4.7.0 Try again later, closing connection. (EHLO)
• EHLO any.dotted.name → 250 (and the full send succeeds)

Verified on v0.7.50; smtp.ts on current main still passes no name, so the bug should still be present.

Suggested fix

Plumb an optional env var through to the transport, e.g.:

name: env.SMTP_EHLO_NAME || undefined,

(plus the env schema entry / helm chart docs). Defaulting to the current behavior keeps it non-breaking; a fancier default could use os.hostname() only when it's a FQDN and otherwise fall back to the configured public app domain.

Workaround for other k8s users

Force the pod's kernel hostname to be a FQDN so nodemailer uses it:

kubectl -n <ns> patch deploy <app-deploy> --type=strategic \
  -p '{"spec":{"template":{"spec":{"hostname":"sim-app","subdomain":"sim-app","setHostnameAsFQDN":true}}}}'

After the rollout, os.hostname() returns sim-app.sim-app.<ns>.svc.cluster.local (contains dots), nodemailer sends it as the EHLO name, and Google's relay accepts it. Confirmed working.

Environment

• Sim v0.7.50 (helm chart 1.4.0), self-hosted on GKE
• Email provider: SMTP (smtp-relay.gmail.com:587, STARTTLS, IP-allowlist relay)