I’ve a few comments, taking into consideration that my expertise is primarily on the openHAB side of things, not the hardware.
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I think you’ll need to develop a whole new case to provide room for a Pi 3. There’s not a whole lot of extra room in there and I bet heating will be a problem.
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Since you need to buy the Pi 3 anyway, why not run a separate OH instance and integrate the HestiaPi with that? See
This will let your HestiaPi run relatively independently from your main home automation which is likely going to be constantly changing and upgrading.
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Upgrades to HestiaPi’s software will become quite challenging as the default upgrade will wipe out all your customization and new stuff you’ve added to the HestiaPi openHAB config. You’ll have to merge/remake your customization after an upgrade which could be an extensive amount of work if it’s hosting your whole home automation.
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NOTE: I have brought the boot time on the HestiaPi down to ten minutes (from thirty) on the RPi 0 but I did so by moving everything to the JSONDB. As a result, if you have your own custom .rules files and the like they will very likely break things unless you remove the HestiaPi ones first.