Is this 24pin to molex power pcb safe?

Maybe I will look for a PSU with 20 sata and double 3/4 of the connectors.
https://pangoly.com/en/product/lc-power-lc1200p-v3-0 not sure how good this lc power is
Hah but with that cost I could probably just buy the same psu again

Could go a little bit more in depth with the 1,5A limit on the pins and voltage drop etc?

Sata Power pins are different than the crimp pins you use for 24/pcie/eps - they don’t slot in, they just kinda sandwich ontop of each other:

If you look at the pin-out, you’ll see that 3.3v, 5v, & 12v each get 3 pins. Each pin is rated for ~1.5amps if I remember correctly. So 54watts max of 12v, 22w of 5v, ~15w of 3.3v

But if one of those pins isn’t making proper contact, you just lost 30% of your output on that rail.

Edit: again I only answer one of your two questions…

Voltage drop; basically the more load there is on a voltage rail (depending on quality of the PSU), the higher the chance that voltage will drop; ie 5v turns into less than 5v. Hardware generally has some tolerance to voltage fluctuations, but only to a certain point - issues causes by unstable voltage are sometimes much less obvious than ‘computer turns off’.

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Corsair RM1200x Shift can power 20 sata drives, and is much easier to work with than a standard ATX power supply. I can vouch that it’s a viable option if one has a wide enough case.

It’s not designed for running 40 HDD though.

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mmh yeah this had been my original plan. Replace both my PSUs with ones that support around ~20 drives natively. Preferably with ones under 1000W.
And just sell or reuse the current ones…
buying 20 stata splitters seems ridiculous in hindsight.

That seems indeed to be the best, safe and cheapest option.

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I know that the 850x has the same 5V rail capacity as the 1200x, and the same number of SATA connectors (the biggest difference is the 12V rail, if not running a big GPU for AI it should be fine).

No comment on anything else, I’m not knowledgeable enough for my opinion to be taken seriously.

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And huge thanks @Fleshmauler you increased my knowledge about this a lot!

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Look here:

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I’d be looking into a large HD case from Supermicro… or second hand.

24, 45, 60 or 90 bay etc

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Yep. This is a solved problem, and suitable hardware is readily available. It isn’t super-cheap, but reasonable if bought used.

Well, if a new case is on the table, a H45 could alos be a nice option.
That one has PCB backpanels, so the sATA power cable issues would also be solved.

Their backplanes are dodgy IMO; Supermicro seem to have much better thought-out kit. But that’s another option.