December 12, 201015 yr The following are the steps laid out for anyone referencing: Great plan and excelent discussion. In the event that your array is packed full of files and you have no place to copy data off the disk you want to replace, I think there might be a variation that would work. Without listing all the steps from bjp999's post here is what would be different. - Remove all drives to be replaced - Insert new parity drive and new data drives (assuming they have been properly partitioned) - backup config (or trust backup from initconfig), assign drives where you want them (including new parity), initconfig, start array and calculate parity - Now, insert the the data drives you removed (could do 1 at a time) into another system that can read them and copy files to the new data drives in the unRAID server Read errors during the parity build or when copying files off the removed drives, would mean reverting to the original configuration, fixing them and starting over, but you would not need to recopy everything you already copied. That is unless you were so unlucky as to get a read error on one of the new drives when when you put them pack in the array. After all files are copied to the new drives, CRC verified and a parity check has been run you can format the old parity drive and recycle the old data drives.
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