>are hard links an option? ie, as root on the e-smith machine,
Yes, if you can give a little more detail to a newbie.
>-move the content of (bay2) to (hd2)
>-use "ln /real/path/ /old/path" to setup a pointer from old->new?
Can you give a little more information? How??? I want to try.
>I don't suppose we have RAID array support for volume spanning at this point

?
I just figured out how to setup a sofware raid, but I reformated the drives as I need all the space I can get for data storage to be used as backup volumes.
>I guess it would be asking too much ..

I'm a newbie trying to learn. Weren't you one once???