With 1.06 and the USB drive installed, the RAID1 array has been functioning perfectly. Both drive LEDs flicker when writing to the DNS, and the drive LEDs alternate between the two disks during large file reads as expected. I have moved hundreds of gigs back and forth between the DNS and other computers with no issues so far. Seems pretty solid to me.
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Also, from an ssh session, I have umounted the /dev/md0 device and run e2fsck on it numerous times and the results are always clean. So I am confident that the array is working properly - even though the 2nd disk doesn't show up consistently on the web status device list.
I doubt its a fun_plug issue, since the drives show up on the STATUS page correctly if fun_plug is running off of the RAID array. Its only when I add the additional USB device into the config that the display screen is wrong. Interesting that this behavior didn't occur under 1.05 firmware.
I certainly don't expect D-Link to spend cycles researching this issue (unless you want to
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) as it is clearly occuring when I'm running an unsupported configuration. But if D-Link ever plans to support external USB disks this could become an issue. Thanks !!