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if i had a budget and need for multiple interconnected 24x boxes, id go for primary with enough external ports to handle any amount of drives comming drive drive_node/slave box and equip rest of the boxes with some extra cheapass board+cpu+ram to power local expander
using 6 cables to get 24x...
forget the pending sectors, you have 4000 realocated sectors, backup yr raid and dismantle it asap
that drive is gone
waranty is probably expired ( 20k poweronhours ) so throw it out
get hdd shiping box.
http://www.aquaphoenix.com/application/sales/products/hdd_box_2_large.jpg
remove drives from server, pack em in the box and for the most part you should be safe.
back when i had 70+ drives at home, i ran spindowns all the time
power/heat savings made enough sense
+ i had proper indexing tools, drive was never brought online if someone just needed to clarify whats on it, they came up only on real datarequest ... and in those cases waiting 10-30s wasmt...
indeed
back in the '04/05 we needed at least 8 drives to achieve 1tb ...
today 10 is done with 3 and almost 50 can be done with 12, with is basicly a desktop design
we truly need 50-100TB+ thread
the case has 6 mini-sas ports
usas2 will provide you with 2 aka 8 ports for drives
you might wana look into m1015 @ ebay and new board with 8 satas onboard + 2 pcie or board with 3 pcie slots