John Hendrikx wrote:
I'm not sure why this keeps going wrong, but I do know I made a mistake
when initially reconstructing the array.  What I did was the following:

# mdadm /dev/md1 --add /dev/hde

Releazing that I didn't want to add the complete drive (/dev/hde) but only
one of its partitions (/dev/hde1) I then did (while it was still
rebuilding):

# mdadm /dev/md1 --fail /dev/hde
# mdadm /dev/md1 --remove /dev/hde

I'm not 100% sure but it *may* have rebuilt the superblock.

do:
 mdadm --examine /dev/hde
 mdadm --examine /dev/hde1

If hde has a superblock then that could be picked up before the hde1 one.

(ah, read more of your email and you were on the right tracks :) )

To fix this do:
 mdadm --zero-superblock /dev/hde

Once all this is done you may want to run a check on the array.

There's probably other stuff going on with partition table caches too - blockdev -rereadpt may make a difference... but I suspect the --zero-superblock will just fix it all on the next boot.

David
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