> shouldnt have to DD the whole disk as zero just the first few blocks.. errrr
> what i  tried at least for a few other problems...

I know - but mdadm was still taking /dev/sda even *without* partitions.
I'm guessing somehow, somewhere, there was some residue from when the disc
may have been in a raid configuration somewhere on another system from
where the disc originated (I have a collection of old discs from a
variety of places where I used to be a sysadmin).

*shrug*

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