> Have you confirmed the hdd must be prepared with fdisk prior to running
> the raidhotadd command?

I can confirm that you must partition the new hard disk like the other disk
in the array.
Linux soft raid works at partition level, you could mirror two partition on
the same disk (only for test purposes).

And raidhotadd must be run for every partition (one immediately following
the other, kernel serializes reconstruction):

raidhotadd /dev/md0 /dev/hdc1
raidhotadd /dev/md1 /dev/hdc5
...

I've some system using RAID1 in production since years, I did many
"rebuilding tests" at the time when RAID 0.90 was being developed.
And, once, I had to change an hd that broke for real.

I can add that the new hd could be different from the old one (if that model
is no longer available), only partition table matters.
One more thing to pay attention to is hd geometry. After first power on with
new unpartitioned hd, geometry will probably be LBA and if the other hd is
CHS, it will be difficult (read impossible) to set up identical partition
table. The solution involves specifing geometry at boot time
(hdc=1234,16,16), partitioning and rebooting. The kernel will derive correct
geometry from PTBL.

The only test I have not repeated recently is to disconnect first IDE hd
(hda) and try booting the machine.
Before the release of the RAID1 aware lilo version you had to do some tricks
with lilo.conf and boot partitions.

Ciao,
Filippo



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