[ It's great when you can pass on knowledge and other "see the light" and
  pass it on in turn :-))
]

Whereas Tom has does it "for real" with his many GB of data depending on it, I 
have never run a RAID5 array (other than 3 cylinders on a single disk!) so am 
free to postulate from my ivory tower ....

I appear to have missed the original message, and whereas I pretty much agree 
with all that has been suggested, but have a few little concerns ....

Before you do anything, ensure you ZAP the broken disk (sda1) !
I don't know how RAID5 works, but it might be willing to reconstruct even if 
it can't get a complete set of event counters. I take this not to be the case, 
or I suspect you wouldn't be in your current position !

Anyway, the simplest HACK is to change the partition table to be something 
other than 0xfd. If sda1 is < 2GB, I have a perl script to manipulate the SB 
(of course, I didn't see that limitation when testing on 4MB partitions!).
Otherwise, if all else fails, use dd to ZAP the SB.

Try using "mkraid --debug /dev/md0" [ I have HACKed mkraid so as not to need 
the unused argument -- I suggest you use a /dev/md* which does not exist, 
"just in case" it tries to actually do something ] to dump the kernel's view 
of the disks. Again, if < 2GB, I my perl script can dump the SB info for you.
Failing that, it should be simple to write a C programme which can do the 
necessary seek and grab the data, so that my script can process it.

My understanding is that "failed-disk"s are totally ignored, and just left as 
holes. In any case, I tend to use "/dev/null" as the failed disk "just in 
case". My belief is thus that a reboot or whatever will not do any harm, and 
will not try to bring the broken disk back into use.  However, using 
"/dev/null" in /etc/raidtab will ensure that it cannot !

When you had done the raidhotadd, don't forget to update /etc/raidtab, as it's 
always good policy to keep it up to date "just in case" (my script generates 
/etc/raidtab format files from the data on disk, so I always have up to date 
info saved on another machine !)

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