So, thanks for help from Gao-Mi and Alex.  Starting a new email thread after
some more work. From my latest on old thread:

On Mon, Jul 01, 2019 at 01:02:58PM -0400, Chris Ross wrote:
> [ installboot limits softraid bootloader to 160kb ]
> 
> Anyone else have an idea what I could try to see why ofwboot seems not to
> be able to load and boot my system from my RAID1 softraid on sparc64?

So, a bunch of work to build my custom world allowing for larger bootloader
in softraid:  I ended up building this new custom softraid onto sd0 and sd1,
and was able to load the debugging ofwboot into it.  But, "it just worked."

:-(  So, I think the issue was that it didn't work for some reason with
my raid1 on sd2 and sd3, but did work loaded from sd0 and sd1.  Still
identifying itself as sd4 after boot, but.  I also dropped back to a
fresh install from an unmodified 6.5 ISO, onto a softraid on sd0/sd1,
and that worked just fine too.

I thought about cutting my losses and just running on sd0/sd1, but then
decided I'll take another few days to rerun the whole process again
onto sd2/sd3.  If I get it to fail there, again, I'll see what the
debug ofwboot shows, and I have a single-disk install on sd1 that I can
build changes with.

Just an update, hopefully I'll have more to report by next week.

                   - CHris

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