> 200 MB for /boot was sensible years ago but now is a joke. since when? All you need is 2 kernels. Have Linux 3.x kernels gotten out of hand? I only use RHEL/Centos5 and 6 and I've never even come close to running out. > reduce the PV size without harm. But I'm unable to decide on a workflow and > loosing data or downtime are not acceptable options... then don't bother. > So I'm begging your help on a suitable workflow to make this happen. A. tell the customer "too bad" buy newer/bigger hard drives already and build new layout on new disks and DD/RSYNC data to new layout Or if you like to play with fire: * reduce filesystem size * lvresize down to match * resize MD member device (eg. http://webapp5.rrz.uni-hamburg.de/SuSe-Dokumentation/manual/sles-manuals_en/manual/raidresize.html) * create partition out of newly available slack space (use kpartx and you should avoid a reboot) * pvcreate on new partition, add to VG and grow LV into new space * resize filesystem _______________________________________________ linux-lvm mailing list linux-lvm@redhat.com https://www.redhat.com/mailman/listinfo/linux-lvm read the LVM HOW-TO at http://tldp.org/HOWTO/LVM-HOWTO/