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Hi,

Bo, 

first, please accept my apologies for putting you through this torture.

Somebody had to test it one day, that day has come.

Second, thank you for persevering with me.

Hopefully, I have found a reasonably simple solution.

Required changes:

Keep the "mismatched CA to vars file" as a warning ONLY, keep that current 
change.

Now, locate this code in function up23_do_upgrade_23():

        up23_verify_new_pki
        up23_verify_current_pki
        up23_verify_current_ca
        up23_backup_current_pki
        up23_create_new_pki
        up23_upgrade_ca
        up23_move_easyrsa2_programs
        up23_build_v3_vars
        up23_create_openssl_cnf

Change that to this (Copy/paste as is):

        up23_verify_new_pki
        up23_create_new_pki
        up23_create_openssl_cnf
        up23_verify_current_pki
        up23_verify_current_ca
        up23_backup_current_pki
        up23_upgrade_ca
        up23_move_easyrsa2_programs
        up23_build_v3_vars

Then, locate this code (Almost at the very end of the entire file):

        upgrade)
                up23_manage_upgrade_23 "$@"
                ;;


Change to this:

        upgrade)
                secure_session
                up23_manage_upgrade_23 "$@"
                ;;


The actual diff is:

@@ -5156,14 +5183,14 @@ up23_do_upgrade_23 ()
        up23_verbose ""
 
        up23_verify_new_pki
+       up23_create_new_pki
+       up23_create_openssl_cnf
        up23_verify_current_pki
        up23_verify_current_ca
        up23_backup_current_pki
-       up23_create_new_pki
        up23_upgrade_ca
        up23_move_easyrsa2_programs
        up23_build_v3_vars
-       up23_create_openssl_cnf
 
        if [ "$NOSAVE" -eq 0 ]
        then
@@ -5734,6 +5761,7 @@ case "$cmd" in
                make_safe_ssl "$@"
                ;;
        upgrade)
+               secure_session
                up23_manage_upgrade_23 "$@"
                ;;
        ""|help|-h|--help|--usage)

This should ensure a temporary session and files can be created.


Finally, run the upgrade like so:

$ EASYRSA_TEMP_DIR="$PWD" VERBOSE=1 easyrsa upgrade pki

If it complains that your new pki already exists then please remove it and try 
once more..

I am cutting the rest of this email for brevity.

Highest regards
Richard
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