Ah no, it is mdadm that's buggy.

The "array md1 already has disks!" infinite loop is fixed in the latest
upstream version (2.6.7).  If you have git access, have a look at commit
"mdadm-2.6.6-1-g1c203a4".  The log says it fixes "autoassemble for
stacked arrays", but it looks like this bug also affects non-stacked
arrays in some circumstances.

At least On Hardy Heron, Ubuntu doesn't patch mdadm at all.  So one
should be able to just install mdadm from source.  Obviously one needs
to take great care if you use MD for your root filesystem.

There are also a worrying number of "fix segfault" commits.  Personally
I think I'll be much happer after manually upgrading mdadm to version
2.6.7.

-- 
long bootup, dmesg full of md: array md1 already has disks!
https://bugs.launchpad.net/bugs/139802
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