rpmurray, I failed to recall that he was able to clone the drives with no errors.
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The error is in the same place every time, which is making us think that it's an error with the data in the array after the array. fsck sees the error, but doesn't seem to make any attempts to fix it - it just exits fatally.
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This made be believe that it did fail at one point, but this was snap not dd.
If he still have the drives cloned install them all and see what happens. The way Snap-Tech explained it to me is. If a drive does not resond with in a set time, it reports a problem, even if all data is good. The problem accours if the SMART reloactes some sectors due to an error. Then the time required to get the spot has increased, due to the detour. Drive is still good. He has the tools required to adjust the drives to work in unison.
I hope the Guardian OS is not this picky.....