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[gunrunnerjohn]

I think I'm out of ideas here.  My take would be to remove the drive and connect it to a PC and recover the data before doing anything else.

[irha]

If you clone the entire drive by connecting both the drives to a pc, would DNS-321 treat them to be in sync? The other option is to ssh in and use command line tools to rebuild the array, at least that would probably give a better idea of where things are failing, but I am not sure if DNS-321 uses the standard linux raid configuration and tools and if they are accessible as command-line tools.

[gunrunnerjohn]

I would not screw around if the data on the drive is your only copy...

[irha]

I am following this thread now to do a manual resync. I am now monitoring the /proc/mdstat for progress and will continue with the rest of the steps and report back.

PS: I had to get the fdisk2 attached to this post to get the manual partitioning to work, as the fdisk that is already there was crashing.

[jamieburchell]

A potentially easier and safer approach would be:

Backup data somewhere
Remove both drives, attach to PC and erase all partitions/zero fill
Check drives for errors/surface scan
Factory reset
Attach both drives in NAS
Format as RAID1
Copy data back

If any of those steps fail, you've got a problem somewhere.

[irha]

I agree, it is a risky operation without having a backup copy. In my case, since I just started consolidating misc. external drives to the NAS solution, I won't have a problem starting over (though I will loose some time).

I have now successfully finished the manual process. Here is what I did:
1. I downloaded fdisk2 from the thread I previously pointed out.
2. Created partitions in the same order and size as on the existing drive.
3. Manually added partition to the array waited for that to finish.
-- /usr/sbin/mdadm --manage --add /dev/md0 /dev/sdx2
4. Manually created ext3 filesystems on the other two partitions
-- /ffp/sbin/mke2fs -j /dev/sdx1
-- /ffp/sbin/mke2fs -j /dev/sdx4
5. Mounted the sdx4 partition
-- mount /dev/sdx4 /mnt/HD_x4
6. Forced an update of the hd_magic_num file for the web UI
-- /usr/sbin/hd_verify -w

Now the UI seems to happy about the state of the array. My only concern is about the steps in 4 and 5 that nobody seem to have mentioned as having to do. I am not sure if I am missing any more steps, e.g., should I be adding an fstab entry somewhere?