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Here are the notes I took while manually expanding an non-LVM encrypted RAID1 array on an Ubuntu machine. My original setup consisted of a 1 TB drive along with a 2 TB drive, which meant that the RAID1 array was 1 TB in size and the second drive had 1 TB of unused capacity. This is how I replaced the old 1 TB drive with a new 3 TB drive and expanded the RAID1 array to 2 TB (leaving 1 TB unused on the new 3 TB drive). Partition the new drive In order to partition the new 3 TB drive, I started by creating a temporary partition on the old 2 TB drive ( /dev/sdc ) to use up all of the capacity on that drive: $ parted /dev/sdc unit s print mkpart print Then I initialized the partition table and creating the EFI partition on the new drive ( /dev/sdd ): $ parted /dev/sdd unit s mktable gpt mkpart Since I want to have the RAID1 array be as large as the smaller of the two drives, I made sure that the second partition ( /home ) on the new 3 TB drive had: the same start position as the second partition on the old drive the end position of the third partition (the temporary one I just created) on the old drive I created the partition and flagged it as a RAID one: mkpart toggle 2 raid and then deleted the temporary partition on the old 2 TB drive: $ parted /dev/sdc print rm 3 print Create a temporary RAID1 array on the new drive With the new drive properly partitioned, I created a new RAID array for it: mdadm /dev/md10 --create --level=1 --raid-devices=2 /dev/sdd1 missing and added it to /etc/mdadm/mdadm.conf : mdadm --detail --scan >> /etc/mdadm/mdadm.conf which required manual editing of that file to remove duplicate entries. Create the encrypted partition With the new RAID device in place, I created the encrypted LUKS partition: cryptsetup -h sha256 -c aes-xts-plain64 -s 512 luksFormat /dev/md10 cryptsetup luksOpen /dev/md10 chome2 I took the UUID for the temporary RAID partition: blkid /dev/md10 and put it in /etc/crypttab as chome2 . Then, I formatted the new LUKS partition and mounted it: mkfs.ext4 -m 0 /dev/mapper/chome2 mkdir /home2 mount /dev/mapper/chome2 /home2 Copy the data from the old drive With the home paritions of both drives mounted, I copied the files over to the new drive: eatmydata nice ionice -c3 rsync -axHAX --progress /home/* /home2/ making use of wrappers that preserve system reponsiveness during I/O-intensive operations. Switch over to the new drive After the copy, I switched over to the new drive in a step-by-step way: Changed the UUID of chome in /etc/crypttab . Changed the UUID and name of /dev/md1 in /etc/mdadm/mdadm.conf . Rebooted with both drives. Checked that the new drive was the one used in the encrypted /home mount using: df -h . Add the old drive to the new RAID array With all of this working, it was time to clear the mdadm superblock from the old drive: mdadm --zero-superblock /dev/sdc1 and then change the second partition of the old drive to make it the same size as the one on the new drive: $ parted /dev/sdc rm 2 mkpart toggle 2 raid print before adding it to the new array: mdadm /dev/md1 -a /dev/sdc1 Rename the new array To change the name of the new RAID array back to what it was on the old drive, I first had to stop both the old and the new RAID arrays: umount /home cryptsetup luksClose chome mdadm --stop /dev/md10 mdadm --stop /dev/md1 before running this command: mdadm --assemble /dev/md1 --name=mymachinename:1 --update=name /dev/sdd2 and updating the name in /etc/mdadm/mdadm.conf . The last step was to regenerate the initramfs: update-initramfs -u before rebooting into something that looks exactly like the original RAID1 array but with twice the size. Add a comment