Craig Falconer wrote:
Then two ways to progress....
0    Boot in single user mode
1 Add one new drive to the machine, partition it with similar but larger partitions as appropriate.
2    Then use
        mdadm --add /dev/md3 /dev/sdb4
        mdadm --add /dev/md2 /dev/sdb3
        mdadm --add /dev/md1 /dev/sdb2
        mdadm --add /dev/md0 /dev/sdb1
        sysctl -w dev.raid.speed_limit_max=99999999
3    While this is happening run
        watch --int 10 cat /proc/mdstat
    Wait until all the drives are synched
4 If you boot off this raidset you'll need to reinstall a boot loader on each drive
5    Down the machine and remove the last 320 GB drive.
6    Install the other new drive, then boot.
7    Partition the other new drive the same as the first big drive
8    Repeat steps 2 and 3 but use sda rather than sdb
Once they're finished synching you can grow your filesystems to their full available space
9    Do the boot loader install onto both drives again
10    Then you can reboot and it should all be good.

I have a new drive installed, partitioned and formatted, ready to add to the raidset, first some questions related to the above, to ease my mind before proceeding. Is it necessary to boot to single user mode (and why?) since this will make the machine unavailable to the network as a file server for the duration of the process? Machine is used solely to serve up files. Based on the time it took to re-add the drive last week, it would need to go offline for some hours, and therefore means a very late (start and) finish to a work day or needing to be at a weekend to keep it available to users during working days.

From my reading of man mdadm, it suggests doing a fail and remove of the faulty drive, possibly at the same time as adding a new device, like:
mdadm /dev/md0 --add /dev/sda1 --fail /dev/sdb1 --remove /dev/sdb1

Is this a good process to follow or is it redundant/unnecessary?

Just in case I run into issues reinstalling the boot loader from a live CD, I understand that I would (as an interim measure) be able to boot the machine with a single partition marked as bootable from just the current good drive by disconnecting the new drive?

Finally, I'm somewhat unclear how the resulting partitions are going to work out, current failing drive is /dev/sdb, /dev/sdc holds backups, new larger drive comes up as /dev/sdd. Surely once sdb is physically removed sdc and sdd move up a letter and this messes with adding to the raid array as sdd? Or, is a better approach to do a fail & remove of the failing drive, physically remove it and put the new drive on the same sata connector?

Cheers,
Roger



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