> My problem is that whenever I boot now, the array comes
> up without sda2.  I can raidhotadd sda2 and things are happy
> until the next reboot.

Hmm -- sounds to me like "raidhotadd" isn't re-writing the SB -- sorry, I don't
know how that code works :-(

What does a "mkraid --debug" give you in /var/log/messages ?

If you can grab a copy of the on-disk SB and send me an "od -t x4" (or an
encoded binary) I can unpick it and see what is *actually* there ...
(failing that I can send you a copy of my SB debugging script ...)

> How can I make sda2 act like the other disks?

          ========================================================
          *** IF THERE IS REAL DATA ON IT, DO NOT TRY THIS !!! ***
          ========================================================

(READ NO FURTHER UNLESS YOU ARE A HACKER !!)

My very uneducated guess (I've only recently started using RAID) is that the
following might work:

        raidhotadd it, and wait til it's in sync.
        raidstop the device.
        Now it is known that all data on disk is "correct".
        Whatever "resync" subsequently happens, the result should be correct.
        Update raidtab to have it as a raid-disk
        Run "mkraid -R /dev/md0" (if you are *really* sure you want to).
                Contrary to my interpretaion of what I have read, my current
                belief is that this will ZAP the RAID SB, but not the data.

With the new SB in place, it should all work ...

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