I've tried an old 'bypass': sysctl kern.geom.debugflags=16, but that
didn't help.

Can anyone help me get this new disk installed without having to boot off
a recovery CD? The server is 500 miles away from me and I don't have
direct console access.

Uhmm... This may seem silly, but did you use fdisk to create a slice first
before you tried partitioning?

this is NOT needed. actually i don't do it anywhere.

it just may be sysinstall problem, anything else.
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