> after a disk failure (Software RAID 1 worked fine here) I exchanged
> the bad disk, partitioned the new disk, and started raidhotadd.

Did you set the correct partition ID ?

> /proc/mdstat says that the new disk is resyncing but there is no
> progress at all. There is only 1% of the mirror in sync now and
> the estimated time of completion grows continuously. There is
> a load average of about 1.0 caused by this process.

Are there any (SCSI?) errors in syslog ?

> After several trys I gave up to resync the mirror and started
> the server with the incomplete RAID 1 Array :-(
> 
> Environment:
> Kernel is 2.2.10 with new-raid-style patches applied, auto-detection
> activated and a persistent superblock.

I use 2.2.13 + RAID 0.90 08/24 + raidtools 08/24 in a 4 disk SCSI RAID5 setup.
The server crashed quite often lately due to insufficient cooling of the
CPUs and did a resync after each crash. Never had a problem with that.
SCSI controller is an AIC7895.

Thomas

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