[jontz]

Wowzers...

I am sure that you have already checked all the cables, but have you tried replacing the IDE cable for drive 1?

Since these are WD drives, did you set drive 1 as single master or master with slave present?

The log shows that it tried to add your hot spare back into the array, but it couldn't. I am wondering if you are losing an IDE controller on the motherboard. I don't think you are, but it is always a posibility...

Have you tried another drive? You might have gotten an out-of-box bad drive. You know what Murphey says...