Don't need high availability, portable is a plus, but not a must. Difficult to set up is fine, but MUST be easy to use or automated as much as possible, or i will stop doing it soon as i focus on another project. I do have my old freenas i was thinking about re-purposing. IT's based on AMD hardware though, it might be good enough for a backup, but maybe I should just sell it on ebay and build a dedicated system for this.
If it's only for backup, then I'd have fewer qualms about using the old system, even if it's not "ideal". Part of a healthy backup solution should be testing the data, so when testing, you'll see if anything is going wrong with the old system.
How would the external array work? Just plug a bunch of external usb drives and mount the pool? What would you recommend for the backup pool configuration? RaidZ? I'm worried about having to 'match' pools between my main freenas and the backup.. it may lead to alot of USB drives in a lot of ports. I dont know if the replication tools know when to switch to a new usb drive if a pool needs to span 2 external drives, etc. But if i can just plug in a bunch of 8TB external drives and the replication tools are smart enough to span them like a continuous tape, etc that would be great.
I think you're confusing a bunch of things here.
First, the suggestion about the USB/eSATA array was to plug your array in to you main
desktop computer, and transfer the data over the network to this array. Then you can just format the drives however is convenient. FreeNAS would never know they exist.
Second, the suggestion about large drives was
not meant to be external (though it could work in the correct setup). Rather, I envisioned that you would install one or more additional drives in your new FreeNAS. For separability, you would put these drives in their own pool. You wouldn't need any kind of RAIDZ or mirroring unless you felt the need for that additional layer of redundancy. By putting multiple vdevs in a single pool, ZFS automatically spans them.
There's some misunderstanding about the replication tool. All the replication tool does is copy data from one dataset to another. It's up to you to configure the dataset (and by extension, pool) to do what you want to do. If you want to "spill over" between drives, those drives (vdevs) must be part of the same pool. Be aware that putting multiple bare drives in a single pool is the equivalent of RAID 0, which means an increase in failure risk (coincidentally, this is why the "spill over" analogy is inaccurate: ZFS writes data across the entire pool evenly, and does not fill up one drive and then another). Reviewing Cyberjock's presentation (sticky in the "New to FreeNAS?" forum) might help you get a better handle on the dataset/pool/vdev hierarchy in ZFS.
I have no experience with USB drives as data drives in FreeNAS, though I'd recommend against that even if it's doable, because USB enclosures add an additional layer between ZFS and your drives (for much the same reason that you want to run RAID cards in IT mode).