Hello again Ron! Thanks for that command. Will keep that in mind when it happens again. Although I updated Cloudflared and things have been stable, I believe my issues were most likely tied in with a known Raspberry Pi 4 issue when using the reboot or shutdown command. One of the issues was resolved with a bootloader update, but one issue is hardware/board specific and can’t be actually “resolved” with the current hardware. Something about 3v3 voltage completely dropping during the reboot process and hanging in that state, even after the pi has fully rebooted. This explains why I never had these issues with the very same setup for over a year on the pi 3B+. This causes issues with Fan or SATA hats and explains my hangs and unreachable pi during reboots. I only reboot the pi when making network changes and when rebooting the router so I figured it was an issue with Cloudflared or the pi not acquiring proper DNS connectivity after reboot. I can replicate the issue by simply rebooting the pi. If I safely shutdown, pull the power source for a few seconds, then power the pi back on, I have no connectivity or hanging issues with the pi and haven’t lost connectivity at all. They should have pulled this unit from the shelves and offered a revision immediately as this was exposed by a user over a year ago and was confirmed. But, I guess not enough users use Hats on their pi’s for them to react, but I got stuck with a bum unit.
The reason I started looking at a hardware issue was because I had this setup working great hands off for over a year with no issues on the 3B+. Also, I have several SD cards with cloned images with older backups and they all behaved the same. So, of course I suspected the fan hat as causing the issue as it’s the only hardware that was new to the setup. When researching that I ran into the articles about the Pi 4 and it’s voltage issues during reboots.
Either way it goes, I’m sure that command will come in handy for future troubleshooting purposes. I appreciate the help!