The 39Gi/node Longhorn data disks at 1:1 over-provisioning can't fit the media stack
(plex 20Gi replica failed: 'insufficient storage'). Volumes are thin-provisioned config-only,
so 200% lets the full catalog fit without a disk resize; physical fill risk is low. Also
right-sized plex config (20Gi was excessive for metadata). Prod-grade path: grow the data
disks (WS-STORAGE follow-up).
The un-suspend reconcile stalled: platform Kustomization Ready=False with
'StorageClass/longhorn ... .parameters.numberOfReplicas: expected string, got 3'.
StorageClass.parameters is map[string]string, but kustomize strips the quotes
around the bare "${LONGHORN_DEFAULT_REPLICA_COUNT}" placeholder, so Flux postBuild
substitution produced an unquoted numeric that server-side apply rejects as int.
Hardcode the quoted numeric literal "3" (kustomize preserves those, as "30" shows);
topology is locked at 3 nodes. The replica knob still drives the global default via
defaultSettings.defaultReplicaCount in the helmrelease (a Helm int value, unaffected).
Co-Authored-By: Claude Opus 4.8 (1M context) <[email protected]>
jakman85
