diff --git a/.gitignore b/.gitignore
index 9a08aaea9f..20731ec899 100644
--- a/.gitignore
+++ b/.gitignore
@@ -136,3 +136,6 @@ custom-gcl
 
 # dibble (the seed slinger) — binary lives next to source
 tools/dibble/dibble
+
+# osv-processor binary built from cmd/osv-processor
+/osv-processor
diff --git a/ee/server/googleworkspace/google_workspace.go b/ee/server/googleworkspace/google_workspace.go
index 293d7df9fc..2a29fba14f 100644
--- a/ee/server/googleworkspace/google_workspace.go
+++ b/ee/server/googleworkspace/google_workspace.go
@@ -209,8 +209,8 @@ func groupDisplayName(g *directory.Group) string {
 // (case-insensitive) and guaranteeing the primary email is present and flagged
 // primary — the host↔user linking matches on the primary email.
 func mapEmails(primaryEmail string, raw []directoryEmail) []fleet.ScimUserEmail {
-	seen := make(map[string]int, len(raw)+1)
-	out := make([]fleet.ScimUserEmail, 0, len(raw)+1)
+	seen := make(map[string]int, len(raw))
+	out := make([]fleet.ScimUserEmail, 0, len(raw))
 	for _, e := range raw {
 		addr := strings.TrimSpace(e.Address)
 		if addr == "" {
diff --git a/osv-processor b/osv-processor
deleted file mode 100755
index 60fcbbfac4..0000000000
Binary files a/osv-processor and /dev/null differ
diff --git a/server/fleet/fleet_vars.go b/server/fleet/fleet_vars.go
index bf8910c411..4bece1d261 100644
--- a/server/fleet/fleet_vars.go
+++ b/server/fleet/fleet_vars.go
@@ -55,7 +55,7 @@ func MaybeExpand(s string, mapping func(string, int, int) (string, bool)) string
 	for j := 0; j < len(s); j++ {
 		if s[j] == '$' && j+1 < len(s) {
 			if buf == nil {
-				buf = make([]byte, 0, 2*len(s))
+				buf = make([]byte, 0, len(s))
 			}
 			buf = append(buf, s[i:j]...)
 			name, w := getShellName(s[j+1:])
diff --git a/server/mdm/apple/profile_processor.go b/server/mdm/apple/profile_processor.go
index 52f79f85d4..07eccb3e8a 100644
--- a/server/mdm/apple/profile_processor.go
+++ b/server/mdm/apple/profile_processor.go
@@ -453,7 +453,7 @@ func preprocessProfileContents(
 					ca, ok := smallstepCAs[caName]
 					if !ok {
 						logger.ErrorContext(ctx, "Smallstep SCEP CA not found. "+
-							"This error should never happen since we validated/populated CAs earlier", "ca_name", caName)
+							"This error should never happen since we validated/populated CAs earlier", "known_cas", profiles.KnownCANames(smallstepCAs))
 						continue
 					}
 					logger.DebugContext(ctx, "fetching Smallstep SCEP challenge", "host_uuid", hostUUID, "profile_uuid", profUUID)
@@ -571,7 +571,7 @@ func preprocessProfileContents(
 					ca, ok := digiCertCAs[caName]
 					if !ok {
 						logger.ErrorContext(ctx, "Custom DigiCert CA not found. "+
-							"This error should never happen since we validated/populated CAs earlier", "ca_name", caName)
+							"This error should never happen since we validated/populated CAs earlier", "known_cas", profiles.KnownCANames(digiCertCAs))
 						continue
 					}
 					caCopy := *ca
diff --git a/server/mdm/profiles/profile_variables.go b/server/mdm/profiles/profile_variables.go
index 5baa8e41a2..9e0dd876c4 100644
--- a/server/mdm/profiles/profile_variables.go
+++ b/server/mdm/profiles/profile_variables.go
@@ -6,8 +6,10 @@ import (
 	"encoding/xml"
 	"fmt"
 	"log/slog"
+	"maps"
 	"net/url"
 	"regexp"
+	"slices"
 	"strings"
 
 	"github.com/fleetdm/fleet/v4/server/contexts/ctxerr"
@@ -29,12 +31,20 @@ Once more is needed it should be placed here, and the main replacement logic can
 under server/service folder. Inside the `preprocessProfileContents` under the `fleetVarLoop` loop.
 */
 
+// KnownCANames returns the configured CA names for logging. Names extracted
+// from profile contents must not be logged: after variable substitution the
+// contents can embed secrets (e.g. certificate passwords), so a malformed
+// variable name derived from them could leak secret fragments into logs.
+func KnownCANames[T any](cas map[string]T) string {
+	return strings.Join(slices.Sorted(maps.Keys(cas)), ",")
+}
+
 func ReplaceCustomSCEPChallengeVariable(ctx context.Context, logger *slog.Logger, fleetVariable string, customSCEPCAs map[string]*fleet.CustomSCEPProxyCA, profileContents string) (contents string, replacedVariable bool, err error) {
 	caName := strings.TrimPrefix(fleetVariable, string(fleet.FleetVarCustomSCEPChallengePrefix))
 	ca, ok := customSCEPCAs[caName]
 	if !ok {
 		logger.ErrorContext(ctx, "Custom SCEP CA not found. This error should never happen since we validated/populated CAs earlier",
-			"ca_name", caName)
+			"known_cas", KnownCANames(customSCEPCAs))
 		return "", false, nil
 	}
 	contents, err = ReplaceExactFleetPrefixVariableInXML(string(fleet.FleetVarCustomSCEPChallengePrefix), ca.Name, profileContents, ca.Challenge)
@@ -52,7 +62,7 @@ func ReplaceCustomSCEPProxyURLVariable(ctx context.Context, logger *slog.Logger,
 	ca, ok := customSCEPCAs[caName]
 	if !ok {
 		logger.ErrorContext(ctx, "Custom SCEP CA not found. This error should never happen since we validated/populated CAs earlier",
-			"ca_name", caName)
+			"known_cas", KnownCANames(customSCEPCAs))
 		return "", nil, false, nil
 	}
 	// Generate a new SCEP challenge for the profile
diff --git a/server/mdm/profiles/profile_variables_test.go b/server/mdm/profiles/profile_variables_test.go
new file mode 100644
index 0000000000..b8c06b598c
--- /dev/null
+++ b/server/mdm/profiles/profile_variables_test.go
@@ -0,0 +1,14 @@
+package profiles
+
+import (
+	"testing"
+
+	"github.com/stretchr/testify/assert"
+)
+
+func TestKnownCANames(t *testing.T) {
+	assert.Empty(t, KnownCANames[int](nil))
+	assert.Empty(t, KnownCANames(map[string]int{}))
+	assert.Equal(t, "one", KnownCANames(map[string]int{"one": 1}))
+	assert.Equal(t, "a,b,c", KnownCANames(map[string]struct{}{"c": {}, "a": {}, "b": {}}))
+}