I tried the same thing (simulated loss of disk) with raid 5 on my
system. The disk stayed marked as bad after the reconnect and reboot. My
roommate got a hold of the command line and typed:
raidhotadd /dev/md0 /dev/hde3
where /dev/hde3 was the one I disconnected (duh)
That immediately started the reconstruction process and it completed and
rebooted with no trouble.
I read the other response to your question and I don't know what all
that does for you. Perhaps those are the correct steps for a brand new
unformatted drive. I did not have to do anything with the partitions.
