First of all, I want to thank everyone for their help and the great information that was provided. I was able to get the server up and running last night. After running tests on all of the drives with Spinrite, I found erradic problems on drive 3 / IDE channel 2. It's hard to believe I would have had this trouble with a brand new drive, but things happen. I replaced the drive, rebuilt the array and waited.... So far all is good and no error messages this time. I was able to leave all of the drives at their full capacity and they were recognized as 137 gig drives. I now have somewhere around 385 gigs free as RAID5.