Existing patio is circa 1952; it is about 200 sq ft. I want to double it which means either I remove the existing patio and put all the pavers on crush and run base and sand or I put half of the pavers on sand on patio and the other half on crush and run and sand. Would it be better to set the pavers on the patio in mortar?
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If you leave the patio in place, put a joint of some sort (eg, some edging) at the boundary between the two sections. No matter how hard you try, the two will not "move" together, and any pavers that span the gap will be knocked askew by freeze/thaw cycles, etc.
Try to find pavers that come in 1" in addition to the normal 2.5" thickness. Use 1" pavers in a mud bed on the slab and the thick ones over your base rock and sand.