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Im guessing you swap the drives one by one, syncing raid inbetween?
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No, not if you want the extra space. Doing it that way will preserve the original drive space.
One has installed FreeNAS on a 4500.
I don't use NetVault so I can't comment on it. I can comment on the S10. I have had problem with mine and has determined it to be the controller card (8ch SATA) in the 4500. Mine has already had some repairs on port 2, I need to do some more on port1. Indications are is that there are cold joints (poor solder jobs) at the connector. The stiff heavy cable has broken them down. After 2-3 day of standby mine will start kicking out errors, If I do not reboot it will lock up the 4500.