We recently resized our MDT on two different lustre installation under 
production use and everything worked out smoothly. I did a backup with dd 
before resizing but we didn't need to use the backup image after all:

[r...@mdt1 ~]# e2fsck -f /dev/mdt1_vol/mdt
e2fsck 1.41.6.sun1 (30-May-2009)
lqcdproj-MDT0000: recovering journal
Pass 1: Checking inodes, blocks, and sizes
Pass 2: Checking directory structure
Pass 3: Checking directory connectivity
Pass 4: Checking reference counts
Pass 5: Checking group summary information
lqcdproj-MDT0000: 10485760/10485760 files (0.0% non-contiguous), 
1706638/10485760 blocks

[r...@mdt1 ~]# lvdisplay /dev/mdt1_vol/mdt
   --- Logical volume ---
   LV Name                /dev/mdt1_vol/mdt
   VG Name                mdt1_vol
   LV Size                40.00 GB
   Current LE             10240
   Segments               1
   Allocation             inherit
   Read ahead sectors     auto
   - currently set to     256
   Block device           253:2

[r...@mdt1 ~]# lvextend --size +40G -n /dev/mdt1_vol/mdt
   Extending logical volume mdt to 80.00 GB
   Logical volume mdt successfully resized

[r...@mdt1 ~]# lvdisplay /dev/mdt1_vol/mdt
   --- Logical volume ---
   LV Name                /dev/mdt1_vol/mdt
   VG Name                mdt1_vol
   LV Size                80.00 GB
   Current LE             20480
   Segments               2
   Allocation             inherit
   Read ahead sectors     auto
   - currently set to     256
   Block device           253:2

[r...@mdt1 ~]# e2fsck -f /dev/mdt1_vol/mdt

[r...@mdt1 ~]# resize2fs /dev/mdt1_vol/mdt
resize2fs 1.41.6.sun1 (30-May-2009)
Resizing the filesystem on /dev/mdt1_vol/mdt to 20971520 (4k) blocks.
The filesystem on /dev/mdt1_vol/mdt is now 20971520 blocks long.

[r...@mdt1 ~]# e2fsck -f /dev/mdt1_vol/mdt


Nirmal
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