I'm running 2.2.12 and raidtools/patches from 19990824.
I'm trying to create a raid-1 partition with the "failed-disk" feature
to transfer existing data from one of the partitions.

raiddev /dev/md6
        raid-level              1
        nr-raid-disks           2
        nr-spare-disks          0
        chunk-size              64
        persistent-superblock   1
        device                  /dev/sdb6
        raid-disk               0
        device                  /dev/sda6
        raid-disk               1
        failed-disk             1

So I have sda6 mounted (shouldn't be a problem) and try to 
create the raid partition:

% mkraid /dev/md6
handling MD device /dev/md6
analyzing super-block
disk 0: /dev/sdb6, 6964146kB, raid superblock at 6964032kB
disk 1: /dev/sda6, failed
mkraid: aborted, see the syslog and /proc/mdstat for potential clues.

Hmm, syslog messages are:

Sep 29 05:10:08 carve kernel: bind<sdb6,1>
Sep 29 05:10:08 carve kernel: blkdev_open() failed: -19
Sep 29 05:10:08 carve kernel: md: [dev 00:00] has zero size, marking faulty!
Sep 29 05:10:08 carve kernel: md: error, md_import_device() returned -22

% cat /proc/mdstat
Personalities :
read_ahead not set
md6 : inactive sdb6[0] 0 blocks
unused devices: <none>

Any ideas what's wrong here?

Both disks are identically partitioned:
Disk /dev/sda: 255 heads, 63 sectors, 1106 cylinders
Units = cylinders of 16065 * 512 bytes

   Device Boot    Start       End    Blocks   Id  System
/dev/sda1   *         1         9     72261   83  Linux
/dev/sda2            10      1106   8811652+   5  Extended
/dev/sda5            10       140   1052226   83  Linux
/dev/sda6           141      1007   6964146   83  Linux
/dev/sda7          1008      1073    530113+  82  Linux swap
/dev/sda8          1074      1106    265041   83  Linux

Disk /dev/sdb: 255 heads, 63 sectors, 1106 cylinders
Units = cylinders of 16065 * 512 bytes

   Device Boot    Start       End    Blocks   Id  System
/dev/sdb1   *         1         9     72261   83  Linux
/dev/sdb2            10      1106   8811652+   5  Extended
/dev/sdb5            10       140   1052226   83  Linux
/dev/sdb6           141      1007   6964146   83  Linux
/dev/sdb7          1008      1073    530113+  82  Linux swap
/dev/sdb8          1074      1106    265041   83  Linux

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