I made yet another 2.5" to 3.5" form factor disk adapter. This one is primarily intended to be placed into 3.5" HDD hot swap bays, which can commonly be found in many server chassis or even midi or big tower configurations. It is designed so that the SATA connectors perfectly line up. I use it mainly for cloning and backing up laptop HDDs or older 2.5" SDDs. In contrast to other designs, this one aims to support all possible different 2.5" disk heights (see Wikipedia). To achieve each of them, fillers are in use, which are required for some hot swap mechanics because otherwise the lever does not push the disk out. It depends on your respective bay whether you need fillers after all. Anyway, in common, different disk heights require different filler sizes:

• 5 mm disk: 14 mm static filler or 4 + 2.5 + 3 + 2.5 + 2 mm modular fillers
• 7 mm disk: 12 mm static filler or 4 + 2.5 + 3 + 2.5 mm modular fillers
• 9.5 mm disk: 9.5 mm static filler or 4 + 2.5 + 3 mm modular fillers
• 12.5 mm disk: 6.5 mm static filler or 4 + 2.5 mm modular fillers
• 15 mm disk: 4 mm static filler
• 19 mm disk: no filler

(Take a look at the diagram in the gallery if you are unsure about your particular disk)

Use the four lateral or two bottom standard holes if you want to mount the whole adapter onto a regular frame for 3.5" HDDs. Fillers are optional in that use case. There are also eight non-standard bottom holes for any other mounting purpose.

Required Hardware:

• 2x 6 mm #6-32 UNC or M3 screws (It depends on your particular disk vendor and type whether you require imperial or metric screws)
• 2x M3 nuts + 2x M3 countersink screws (Length depends on the total filler height + 4mm)
• 2-4x #6-32 UNC screws (If you want to mount the adapter onto a 3.5" frame - Don't use metric screws! They have a smaller thread pitch and diameter!)

Printing:

• Filament: PETG is good, ASA is best (Don't use PLA! Disks warm up.)
• Perimeters: 3+
• Infill: 15% Gyroid, Grid or Rectlinear
• Layer height: ≤ 0.25 mm
• Supports: No
• Nozzle: 0.4 mm

History:

• 23-07-31: 1.1.1 Fix circular overhanging perimeter in the filler mounting holes
• 23-07-30: 1.1.0 Fix lateral standard holes, Add bottom standard holes, Add bottom non-standard holes, Thanks to Agent942
• 23-07-09: 1.0.0 Initial release