A softraid mirror rebuild on a volume with 4096-byte sectors fails at 
approximately 12% with:

softraid0: could not create read io

sr_rebuild() maintains lba and sz variables in 512-byte DEV_BSIZE units but 
places these values directly into READ(16) and WRITE(16) CDBs. 
sr_validate_io() subsequently interprets the CDB values as native-sector units 
and multiplies them by ssd_secsize / DEV_BSIZE.

With 4096-byte sectors, the effective offset is therefore multiplied by eight. 
Validation reaches the end of the volume after roughly 1/8 (12.5%) of the 
rebuild and rejects the read request.
The CDB LBA and transfer length should be divided by:

ssd_secsize / DEV_BSIZE

before being encoded. The issue affects both RAID1 and RAID1C because they 
share the generic sr_rebuild() implementation.
A patched 7.9-current GENERIC.MP got past the 12% mark without issues.

greets
Dariusz Świderski
—
A mouse is a device to select which xterm to type into


diff --git a/sys/dev/softraid.c b/sys/dev/softraid.c
--- a/sys/dev/softraid.c
+++ b/sys/dev/softraid.c
@@ -4677,13 +4677,16 @@ sr_rebuild(struct sr_discipline *sd)
 {
        struct sr_softc         *sc = sd->sd_sc;
        u_int64_t               sz, whole_blk, partial_blk, blk, restart;
+       u_int32_t               blks_per_sec;
        daddr_t                 lba;
        struct sr_workunit      *wu_r, *wu_w;
        struct scsi_xfer        xs_r, xs_w;
        struct scsi_rw_16       *cr, *cw;
        int                     c, s, slept, percent = 0, old_percent = -1;
        u_int8_t                *buf;
 
+       blks_per_sec = sd->sd_meta->ssdi.ssd_secsize / DEV_BSIZE;
+
        whole_blk = sd->sd_meta->ssdi.ssd_size / SR_REBUILD_IO_SIZE;
        partial_blk = sd->sd_meta->ssdi.ssd_size % SR_REBUILD_IO_SIZE;
 
@@ -4736,15 +4739,19 @@ sr_rebuild(struct sr_discipline *sd)
                xs_r.cmdlen = sizeof(*cr);
                cr = (struct scsi_rw_16 *)&xs_r.cmd;
                cr->opcode = READ_16;
-               _lto4b(sz, cr->length);
-               _lto8b(lba, cr->addr);
+               /*
+                * lba and sz are in DEV_BSIZE blocks, while SCSI CDB addresses
+                * and lengths are in logical sectors.
+                */
+               _lto4b(sz / blks_per_sec, cr->length);
+               _lto8b(lba / blks_per_sec, cr->addr);
                wu_r->swu_state = SR_WU_CONSTRUCT;
                wu_r->swu_flags |= SR_WUF_REBUILD;
                wu_r->swu_xs = &xs_r;
                if (sd->sd_scsi_rw(wu_r)) {
                        printf("%s: could not create read io\n",
                            DEVNAME(sc));
-                       goto fail;
+                       goto fail_wu;
                }
 
                /* setup write io */
@@ -4756,15 +4763,15 @@ sr_rebuild(struct sr_discipline *sd)
                xs_w.cmdlen = sizeof(*cw);
                cw = (struct scsi_rw_16 *)&xs_w.cmd;
                cw->opcode = WRITE_16;
-               _lto4b(sz, cw->length);
-               _lto8b(lba, cw->addr);
+               _lto4b(sz / blks_per_sec, cw->length);
+               _lto8b(lba / blks_per_sec, cw->addr);
                wu_w->swu_state = SR_WU_CONSTRUCT;
                wu_w->swu_flags |= SR_WUF_REBUILD | SR_WUF_WAKEUP;
                wu_w->swu_xs = &xs_w;
                if (sd->sd_scsi_rw(wu_w)) {
                        printf("%s: could not create write io\n",
                            DEVNAME(sc));
-                       goto fail;
+                       goto fail_wu;
                }
 
                /*
@@ -4826,6 +4833,10 @@ abort:
        if (sr_meta_save(sd, SR_META_DIRTY))
                printf("%s: could not save metadata to %s\n",
                    DEVNAME(sc), sd->sd_meta->ssd_devname);
+       goto fail;
+fail_wu:
+       sr_scsi_wu_put(sd, wu_r);
+       sr_scsi_wu_put(sd, wu_w);
 fail:
        dma_free(buf, SR_REBUILD_IO_SIZE << DEV_BSHIFT);
 }

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