Kevin Oberman wrote:
Sorry. I read that there was no /dev/ad0s3, so there was no reason to
ask for the bsdlabel output.

First, the slicing looks good. All of the numbers are reasonable and add
up correctly.

I now must suspect it's a GEOM issue. It looks like GEOM is not tasting
the drive properly, but this gets out of my realm of expertise. I would
suggest getting the dmesg from a verbose boot and posting it along with
your kernel config somewhere so that people can examine them. And let us
know when the sources were updated.
I suspect I will not be the one to find anything, though. Everything
looks fine to me...except that it does not work. :-(

I don't know what I did differently this time, but I finally got it to work. Here are the steps I took. May not be the best method but it got the slice created and mountable. I didn't like all the reboots but they seemed to make a difference.

1) Ran sysinstall. Created slice ad0s3 in fdisk using the remaining portion of the disk (just so I don't have to go through this again). Wrote changes here. Rebooted. 2) Checked /dev. /dev/ad0s3 and /dev/ad0s3c finally exist, therefore off to a better start. 3) Ran sysinstall again. Created /d partition in label editor. Wrote changes. Rebooted.
4) Checked /dev.  /dev/ad0s3d is now there.

It was at this point that I tried to mount the partition, which failed with an incorrect super block error. Then it occurred to me that I never actually saw newfs run from sysinstall like it usually does during a fresh install or adding a new disk. So I did one more step:

5) newfs /dev/ad0s3d.

The partition was able to be mounted.

Here are some caveats to this whole thing, for those that are interested:

- Needed to run 'sysctl kern.geom.debugflag=16' every time I needed to write a change to the disk after a fresh boot, since it was a new partition on the disk for the running system. - sysinstall reported that the geometry was incorrect for this disk, so it used a "more likely geometry." I don't remember the values it chose, but when I tried to put in the ones that my BIOS reported it didn't like those either. So your suspicions of a GEOM issue may have been well-founded initially.

I would post a verbose dmesg and kernel config as suggested, but since everything works now I don't know how useful or necessary it would be to anyone else who might encounter this problem. The whole thing was rather mysterious to me from the get-go, quite honestly.

Thanks,
-Jason

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