Archive for December, 2025

Part 8: DIY UNRAID NAS: Preparing the Zero-Downtime NVMe Upgrade (512GB -> 4TB)

Tuesday, December 9th, 2025

DIY UNRAID NAS Part 8: Preparing the Zero-Downtime NVMe Upgrade

Welcome back to Hancock’s VMware Half Hour and to Part 8 of the DIY UNRAID NAS build series.
In this episode, I walk through the planning and preparation for a zero-downtime NVMe cache
upgrade on my homelab UNRAID NAS, running on an Intel NUC 11 Extreme.

The goal of this two-part upgrade is to move from a single 512 GB XPG NVMe cache device
to a pair of Samsung 990 PRO 4 TB NVMe SSDs, ending up with a high capacity Btrfs RAID 1
cache pool for VMs, Docker, and PCIe passthrough workloads. Part 8 focuses on the design,
constraints, and first hardware changes. Part 9 completes the migration and final Btrfs rebalance.

Video: DIY UNRAID NAS Part 8

You can watch the full episode on YouTube here:

DIY UNRAID NAS – Part 8: Preparing the Zero-Downtime NVMe Upgrade

What This Episode Covers

Part 8 is all about understanding the current environment, identifying limitations in UNRAID,
and laying the groundwork for a non-destructive storage upgrade. In the video, I cover:

How my UNRAID array and cache devices are currently configured.
The future hardware specifications for the homelab UNRAID NAS.
Plans for using enterprise U.2 NVMe devices in future expansions.
Why we cannot simply create another cache pool in UNRAID to solve this.
A staged plan to replace the old 512 GB XPG NVMe with 4 TB Samsung 990 PRO drives.
How to safely stop Docker and virtual machines before making hardware changes.
Using PCIe passthrough (VMDirectPath I/O) to present NVMe devices directly to a Windows 11 VM.
Updating Samsung 990 PRO firmware from within the passthrough VM using Samsung Magician.
Confirming that all Samsung NVMe drives are genuine and authenticated.
Reviewing the NVMe slot layout in the Intel NUC 11 Extreme (2 x Gen 3 and 2 x Gen 4).

Chapter Breakdown

Here is the chapter list from the video for quick navigation:

00:00 – Intro
00:05 – Welcome to Hancock’s VMware Half Hour
00:47 – This is Part 8 DIY UNRAID NAS
01:21 – Explanation of UNRAID and how I have set up UNRAID
04:20 – Explanation of UNRAID array and cache devices
04:51 – Future specifications for homelab UNRAID NAS
05:54 – Future use of enterprise NVMe U.2 device
09:42 – I have a cunning plan says Andy
12:02 – We cannot create another cache pool
12:56 – Stop Docker and VMs
13:10 – Shutdown ESXi on UNRAID
13:28 – Shutdown Windows 11 on UNRAID
14:22 – New NVMe installed, old XPG removed
15:16 – PCIe passthrough demonstration configuration for UNRAID VMs
17:14 – Restart NAS
17:29 – NVMe devices are enabled for PCI passthrough
18:11 – VMware VM Direct I/O (PCI passthrough) explained
18:46 – Configure Windows 11 VM for PCI passthrough
20:00 – Samsung Magician advising firmware update available
20:48 – Update firmware of Samsung 990 PRO from Windows 11
23:14 – Confirmation that all Samsung NVMe are authenticated
26:22 – NVMe slots in Intel NUC 11 Extreme are 2 x Gen 3 and 2 x Gen 4
27:06 – Remove NVMe devices from Windows 11 VM

The Cunning Plan: A Staged, Non-Destructive NVMe Upgrade

The key challenge in this build is upgrading from a 512 GB NVMe cache to larger 4 TB devices
without wiping the array or losing data. Because UNRAID cannot create an additional cache pool
in this configuration, we need a staged process.

In Part 8, I outline and begin the following upgrade path:

Review the current UNRAID array and cache configuration.
Plan the future target: dual 4 TB NVMe Btrfs RAID 1 cache pool.
Shut down Docker and VM services cleanly.
Power down the NAS and remove the old XPG NVMe.
Install the first Samsung 990 PRO 4 TB NVMe drive.
Boot the system and confirm the new NVMe is detected.
Use PCIe passthrough to present the NVMe to a Windows 11 VM for firmware checks and updates.
Update NVMe firmware using Samsung Magician and validate that the drive is genuine.

The actual Btrfs pool expansion and final dual-drive RAID 1 configuration are completed
in Part 9, where the second 4 TB NVMe is installed and the cache pool is fully migrated.

PCIe Passthrough and Firmware Updates

A significant part of the episode is dedicated to demonstrating PCIe passthrough
(VMDirectPath I/O) from VMware ESXi into UNRAID and then into a Windows 11 virtual machine.
This allows the Samsung 990 PRO NVMe to be exposed directly to Windows for:

Running Samsung Magician.
Checking for and applying firmware updates.
Verifying drive health and authenticity.

This approach is particularly useful in homelab environments where the hardware is
permanently installed in a server chassis, but you still want to access vendor tools
without moving drives between physical machines.

Intel NUC 11 Extreme NVMe Layout

Towards the end of the video, I review the NVMe slot layout inside the Intel NUC 11 Extreme.
This platform provides:

2 x PCIe Gen 4 NVMe slots.
2 x PCIe Gen 3 NVMe slots.

Understanding which slots are Gen 3 and which are Gen 4 is critical when deciding where to place
high performance NVMe devices such as the Samsung 990 PRO, especially when planning for
future workloads and potential enterprise U.2 NVMe expansion.

What Comes Next in Part 9

Part 8 ends with the new 4 TB NVMe installed, firmware updated, and the environment ready
for the next stage. In Part 9, I complete the migration by:

Replacing the remaining 512 GB cache device with a second 4 TB Samsung 990 PRO.
Rebuilding the Btrfs cache pool as a dual-drive RAID 1 configuration.
Verifying capacity, redundancy, and performance.

If you are interested in UNRAID, NVMe-based cache pools, or nested VMware and PCIe
passthrough in a small form factor system like the Intel NUC 11 Extreme, this two-part
upgrade is a practical, real-world example of how to approach it safely.

By The Power Of UnRAID – The Secret Reveal Of ESXi And Windows 11 VMs

For the last few episodes of Hancock’s VMware Half Hour, we have been quietly building something a little different.
On the surface it looked like a simple DIY UNRAID NAS project and a couple of Windows 11 P2V demonstrations.
In reality, everything was running inside virtual machines on an UnRAID host.

In Part 7 of the DIY UNRAID NAS series, we finally pull back the curtain and reveal what has really been powering the lab:
UnRAID running nested ESXi and Windows 11 VMs, complete with PCI passthrough.
This post walks through the idea behind the episode, how it ties back to earlier parts, and why I keep saying,
“By the power of UnRAID.”

Recap: Parts 6, 100 and 101

If you have been following along you will have seen:

Part 6 – Installing and testing Samsung 990 PRO NVMe drives in the Intel NUC based NAS.
Part 100 – Performing P2V migrations of Windows 11 systems.
Part 101 – Continuing the Windows 11 P2V work and refining the process.

In those episodes the star of the show appeared to be a physical Windows 11 machine and a separate ESXi host called ESXi052.
In Part 7 we reveal that this was deliberately misleading. Both the Windows 11 system and the ESXi host were in fact virtual machines.

The Secret: Everything Was A Virtual Machine

Part 7 opens by jumping back to those previous episodes and then revealing the twist:

The “physical” Windows 11 machine you saw on screen was actually a Windows 11 VM.
The ESXi host ESXi052 that we used for P2V work was also a VM.
The same VM was used in Part 6 when we installed and tested the NVMe drives.

In other words, the entire recent run of content has been driven by virtual machines on UnRAID.
The NVMe upgrades, the Windows 11 P2Vs, and the ESXi demonstrations were all happening inside VMs, not on bare metal.

Windows 11 With PCI Passthrough

One of the key enabling features in this setup is PCI passthrough on UnRAID.
By passing through hardware devices such as NVMe controllers or GPUs directly into a Windows 11 VM,
we can test and demonstrate “bare metal like” performance while still keeping everything virtual.

In the video we show Windows 11 running with PCI passthrough on UnRAID, giving the VM direct access to the hardware.
This is ideal for lab work, testing, and for scenarios where you want to push a homelab system without dedicating separate physical machines.

Nested ESXi 8.0 On UnRAID

The next part of the reveal is nested virtualization.
UnRAID is hosting a VMware vSphere Hypervisor ESXi 8.0 VM which in turn can run its own VMs.
This gives an incredibly flexible environment:

UnRAID manages the storage, cache, parity and core virtual machine scheduling.
ESXi runs nested on top for VMware specific testing and lab work.
Windows 11 runs as another VM on the same UnRAID host, with PCI passthrough as needed.

With this approach a single Intel NUC based NAS can simulate a much larger lab
while still being compact and power efficient.

By The Power Of UnRAID

To celebrate the reveal I created a fun meme inspired by the classic “By the power of Grayskull” scene.
In our version, “By the power of UnRAID” raises ESXi and Windows 11 high above the NUC,
showing that UnRAID is the platform empowering the whole setup.

Whether you are running nested ESXi, Windows 11 with PCI passthrough, or a mixture of containers and VMs,
UnRAID makes it straightforward to combine storage flexibility with powerful virtualization features.

The Power Of UnRAID In The Homelab

The big takeaway from Part 7 is simple:

A single UnRAID host can consolidate multiple roles: NAS, hypervisor, and workstation.
You can experiment with ESXi 8.0, Windows 11, and PCI passthrough without building a large rack of servers.
By keeping everything virtual you gain snapshots, flexibility, and the ability to rebuild or clone systems quickly.

For homelab enthusiasts, students, and anyone who wants to learn VMware or Windows 11 in depth,
this approach offers a lot of power in a very small footprint.

Watch The Episode

If you want to see the full walkthrough, including the moment the secret is revealed,
watch Part 7 of the DIY UNRAID NAS series on Hancock’s VMware Half Hour.
You will see exactly how the Windows 11 VM, the nested ESXi host, and UnRAID all fit together.

Conclusion

Part 7 closes the loop on a long running lab story.
What looked like separate physical systems were really virtual machines,
carefully layered on top of an UnRAID powered NAS.
By the power of UnRAID, we have been able to demonstrate NVMe upgrades, Windows 11 P2Vs, and ESXi 8.0 testing
all on a single compact platform.

If you are planning a new homelab or want to refresh an existing one,
consider what UnRAID plus nested ESXi and Windows 11 VMs could do for you.

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Part 6: DIY NAS – Installing Two Samsung 990 Pro Gen 4 NVMe M.2 SSD in an Intel NUC 11 Extreme

Monday, December 1st, 2025

Welcome back to Hancock’s VMware Half Hour and to Part 6 of the DIY UNRAID NAS build series.

In this episode I install two Samsung 990 PRO Gen 4 NVMe M.2 SSDs into the Intel NUC 11 Extreme.
The NUC 11 Extreme has a surprisingly capable NVMe layout, providing:

2 × PCIe Gen 4 NVMe slots
2 × PCIe Gen 3 NVMe slots

The video walks through verifying the drives, opening the NUC, accessing both NVMe bays, and installing each SSD step-by-step, including the compute board NVMe slot that is a little more awkward to reach.
The episode finishes in Windows 11 where the drives are validated using Disk Manager and Samsung Magician to confirm that both NVMe SSDs are genuine.

What Is Covered in Part 6

Checking the authenticity of Samsung 990 PRO NVMe SSDs
Accessing both the bottom and compute-board NVMe slots in the Intel NUC 11 Extreme
Installing and securing each NVMe stick
Reassembling the NUC 11 Extreme, including panels, shrouds, NIC and PCIe bracket
Confirming both NVMe drives in Windows 11
Using Samsung Magician to verify that the drives are genuine
Preparing the NVMe storage for use in later parts of the UNRAID NAS series

Chapters

00:00 - Intro
00:07 - Welcome to Hancock's VMware Half Hour
00:29 - In Part 6 we are going to fit Samsung 990 PRO NVMe
01:24 - Intel NUC 11 Extreme has 2 x Gen3, 2 x Gen4 slots
01:45 - Check the NVMe are genuine
04:20 - Intel NUC 11 Extreme - open NVMe bottom panel
05:23 - Install first NVMe stick
06:33 - Remove NVMe screw
07:06 - Insert and secure NVMe stick
07:30 - Secure bottom NVMe panel cover
08:40 - Remove PCIe securing bracket
08:54 - Remove side panel
09:11 - Remove NIC
09:44 - Remove fan shroud
09:59 - Open compute board
12:23 - Installing the second NVMe stick
14:36 - Secure NVMe in slot
16:26 - Compute board secured
19:04 - Secure side panels
20:59 - Start Windows 11 and login
21:31 - Check in Disk Manager for NVMe devices
22:40 - This Windows 11 machine is the machine used in Part 100/101
22:44 - Start Disk Management to format the NVMe disks
23:43 - Start Samsung Magician to confirm genuine
25:25 - Both NVMe sticks are confirmed as genuine
25:54 - Thanks for watching

About This Build

This DIY NAS series focuses on turning the Intel NUC 11 Extreme into a compact but powerful UNRAID NAS with NVMe performance at its core.
The Samsung 990 PRO NVMe drives installed in this part will provide a significant uplift in storage performance and will feature heavily in later episodes when the NAS is tuned and benchmarked.

Support the Series

If you are enjoying the series so far, please consider supporting the channel and the content:

Like the video on YouTube
Subscribe to the channel so you do not miss future parts
Leave a comment or question with your own experiences or suggestions
Follow along for Parts 7, 8, 9 and beyond

Thank you for watching and for following the build.

Gear Used

Kingston Fury 64 GB DDR4 RAM –
https://amzn.to/4i7RhZs
512 GB XPG GAMMIX NVMe SSDs –
https://amzn.to/4o3eLAf
Intel NUC 11 Extreme (Beast Canyon) –
https://amzn.to/4p8aNHh
WERPOWER M.2 to U.2 (SFF-8639) PCIe NVMe SSD Cable – PCIe NVMe U.2 (SFF-8639) –
https://amzn.to/4pbou8m
Samsung 990 EVO Plus, 4 TB, PCIe 4.0 x4 / 5.0 x2, NVMe 2.0, NVMe M.2 (2280), Internal SSD, MZ-V9S4T0BW –
https://amzn.to/4o269Ka
Samsung 990 PRO NVMe M.2 SSD, 4 TB, PCIe 4.0 –
https://amzn.to/4hZx2Ng

More From Hancock’s VMware Half Hour

Enjoy the build and stay tuned for upcoming parts where we continue configuring UNRAID and optimising the NAS.
Do not forget to like, comment and subscribe for more technical walkthroughs and builds.

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Buy Me an Espresso Coffee –
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https://www.paypal.com/paypalme/AndrewHancock
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https://meltonbyhoney.com/

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Tags: 990pro, disk, DIY, Extreme, gen3, gen4, Hardware, homelab, Install, Intel, M2, NAS, NUC, NVMe, Samsung, server, SSD, storage, UnRAID, upgrade, Virtualization, VMware, windows
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