PoorNAS: DIY USB JBOD Hotswap Storage 4 Bay 2.5" 20TB HDD Enclosure

I have a need for multimedia storage where capacity can be increased as needed. I want to use 2.5"HDDs, because they are silent and low power consumption.

GOALS

• USB 3.0 connector
• Uses 2.5" HDDs
• Fits 15mm 5TB drives
• Small
• Silent
• Hot swap
• Add HDD as needed
• Active cooling

In fact PoorNAS is not a NAS but only USB enclosure but I plan to connect it to the OpenWRT router with Samba installed.

1. USB 3.0 hub (Be careful all hubs looks same but some of the hubs are only 3xUSB2.0+1xUSB3.0, also ensure USB HUB prevents back power from hub to host, on one I needed to cut +5V circuit, second one has protection diode built in)
2. 4xZexmte USB 3.0 To SATA Adapter (20cm cable, no external power needed, if you choose different one, the 3d print will not fit. Also I tested different adapter from different manufacturer, but it was not able to read existing data under Linux, so no go)
3. 5V 4A Laptop AC Adapter Charger for Lenovo Miix (In theory you can use any 5V 4A+ 3.5mmx1.5mm adapter, but most of them on AliExpress are fake 4A not capable of spinning 4 drives)
4. 80mmx20mm 5V silent fan + fan grill
5. PWM Fan Temperature Speed Controller (choose 5V with power off)
6. 4xSeagate Barracuda 5TB 2.5" (or any other 2.5" sata HDD/SSD, I personally choose external ones in box and disassemble - they are cheaper. WD box drives not fit, because they have USB soldered. Also keep in mind 5TB 2.5" uses SMR, so it is slow for frequently modified files, but fine for write once multimedia and backup)
7. Computer PC Case 2.5" Mount Screw M3x4.8mm
8. Micro Screws

3D Print following models. HDD Frame and sata holder needs to be printed 4x. Be creative with colors, not like me ;)

1. Solder power connector/fan controller wires to usb hub
2. Connect fan to controller
3. Setup fan controller (I followed this video and after 1 hour or clicking it somehow started to work, but don't ask me how I did it)
4. Set min and max speed
5. Off < 35°C
6. Min = 35°C
7. Max >=50°C

1. Disssasemble USB SATA cables and mout it to 3D printed holders
2. One by one insert it to front box rails and adjust height according to HDD

The fan controller has only one temperature sensor, but we have 4 drives. I solved it using aluminum foil rolled and inserted into corner. The thermal sensor will be inserted inside of the roll on final assembly.

1. Connect all usb cables
2. Insert thermal sensor into heat spreader
3. Put front and back together
4. Insert one or more drives
5. Connect to OpenWRT router & setup Samba, HDIdle

USB drives are not bad, but are far from ideal solution for backup important data. So I am already thinking about improvement, real 5 bay NAS using single board computer + OpenMediaVault + MergeFS + SnapRaid + Staggered spin up and more. Anyway if you like it, you can buy me a coffee!