Btrfs balance crashed now no free space on disk

My guess would be the metadata usage got jacked up so high from all the hacking around you did on this new drive in this thread and this thread. Instead of just copying the files over in a normal manner there was a lot of…experimentation.

For example:

I don’t think the filesystem is the issue.

If you do a reinstall and just copy your stuff over with cp -a or rsync -a instead of all the tomfoolery with snapshots, subvolumes, partition cloning, etc my guess is you will have all your stuff but the metadata will remain modestly sized.

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