I have a completely different setup, but the same problem.

Resync gets to about 75% of 300Gb in RAID1 on two SATA disks. The crash brings 
down the whole machine with no logging.

The only slightly unusual thing is that the output of mdadm --examine
/dev/md0 shows that the number of the two devices sda5 and sdb5 are not
"0" and "1", but "2" and "0". This happened after I booted a gutsy
kernel, it assigned one drive to sdc, and despite UUIDs, this messed up
the array, so I added sdc5 instead of sdb5. I then switched back to
feisty kernel, and sda reappeared, but again not in the array (now
composed of sdb and sdc), and again degraded.


Finally, I readded sda, so I should have been back to the original situation, 
however, I now have sda listed as drive "2" (as shown in square brackets on 
first line of mdadm --examine /dev/md0 output) and sdb as drive "0".

This is not good, as it now hangs the machine completely between 60% and
80% resync. I'm now running a second resync using 'watch', so I'll see
if it is at exactly the same spot that it crashes.

-- 
Boot hang, apparently blocking on SW RAID rebuild
https://bugs.launchpad.net/bugs/22673
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