[jontz]

Originally Posted by rpmurray

This is exactly what I did. Except it was doing a disk check of the RAID after I turned it back on, so I waited until it was done before telling it that the new drive was a hot spare. And it took less than 6 hours for it to tell me that the rebuild failed .

From the log it looks like it tried to pull the drive into the array, but failed. I didn't do any disk config other than telling it that the new drive was a spare. It had already formatted it on it's own.

I don't know what to make of the SMART warnings. Up till now I'd always assumed that the drive was tossing them out, but since this is a new drive, I'm wondering if something else is going on.

As soon as I get finished checking that the backup completed successfully I'll try to reformat Drive 1 again and see if it'll work this time. If that doesn't work, I have another new spare I can try installing to see what happens.

Interesting. I know that you said you hadn't replaced the IDE cable yet. I'd try that just for kicks.

I'll be interested in seeing what happens when you re-format and/or replace the drive.