Need to add capacity to full RN104 consisting of 2 JBOD volumes.

If you use the home folders, you do need to back up the home folder contents. 

The system ought to migrate them to "new", but that's another behavior I wouldn't depend on myself.  You are going down a path that isn't well-trodden (and I suspect not well tested by Netgear).

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WiredRacing wrote:

 

2.5) Can I rename it now so that when I import it it'll come back in as "replicated" or once it's exported it's "gone" until reinstalled?

No.  The volume will disappear when you export it.  And you can't rename volumes in the Web UI,

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WiredRacing wrote:

6) Copy the contents of the "Primary" to the "New" Volume (I suspect it's ideal to do this via SSH rather than the browser-based ReadyNAS management tool) 

7) Delete the "Primary" volume

8) Recreate the old "Primary" volume shares, on the "New" volume.

9) Remove the Primary Drives

10) Move the 10TB Drive to Bay 1 (no problems moving active volumes betweens bays I'm assuming?)

The order here is wrong.  You need to 

6) Create new shares (with unique names) on "new" - relating the names to the shares on "primary"

7) copy the data in the shares to "new"

8) Destroy the primary volume

9) Power Down

10) Remove the Primary Drives and move "new" to slot one

11) Power Up

12) Rename the shares on "new' to match the original names on "primary".

As I said earlier, you can't rename "new", so pick a name you can live with for the life of the volume.

As noted above, you need to create new shares on "New" - with names that are unique across all volumes.  After that you can either copy with SSH or with Web UI backup jobs.  You definitely don't want to create the shares with ssh.  They are BTRFS subvolumes - not ordinary folders.  And you don't want to copy hidden folders on "primary" as they are managed by the ReadyNAS application software.  Don't try to copy snapshots either.

Be careful with ssh - you could easily break the Readynas application software if you try to do this manually.  It's safer to use backup jobs to copy the data (one for each share), and the speed will be the same.

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WiredRacing wrote:

 

11) Install one of the 3TB drives from Primary into Bay 2

12) Install the "Replicated" drives back into Bay 3 and 4. If 2.5 above isn't possible, does it ask me to choose a new name for it? Changing it's name is fine. 

13) Create another JBOD volume "Extra" with the 3TB drive in Bay 2.

 

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I haven't played much with export.  I did it once accidentally a long time ago, and if I remember correctly I ended up losing the volume.  Sandshark has used it more (and more recently), so hopefully he will chime in .

But I think these steps aren't quite right.  I suggest

11) Power down (again)

12) install the "replicate" disks (preserving slot order).

13) power up, and see if it mounts.   The name can't be changed.

The power down might not be needed.  Netgear doesn't say - the kb article just says that "The volume will be exported for cold import on another ReadyNAS" without explanation.  But I think it likely is needed.  Although you could potentially do this step when the NAS was powered down before, I wouldn't do that either.  I think the risk is less if you don't combine these steps.

"Replicate" might not remount - since you aren't importing it to another ReadyNAS, you are attempting to import it to the same ReadyNAS (with the same OS partition and configuration).  That is what I tried to do years ago when I accidentally exported - and that didn't work for me.  If it doesn't remount for you either, then you will need to get advice here or from paid support.  Or create a new volume and accept the data loss.

If it does remount:

14) hot insert the 3 TB drive into slot 2

15) format it via the volume page

16) create the "extra" volume

Then if the home folders are gone (and you use them), you need to connect to the NAS with SMB using each user's credentials.  That should recreate the home folders.  As you do that, restore the contents of each home folder with drag-and-drop using a backup.,