John,
Tried that a few times. The first time it went off and said it was rebuilding the partition. Then when I looked at the array after it was finished it was still [U_]. Restarted the machine and still [U_]...
The second go just said the disk was busy. Hang on, I'll run that command again and tell you exactly what the error is:
[root@gateway log]# /sbin/raidhotadd /dev/md1 /dev/hdb6
/dev/md1: can not hot-add disk: disk busy!
Having just re-trolled the logs, I think the secondary disk has "had issues". It seems the BIOS has gone silly and detected it as an 8GB volume:
Jan 26 12:56:15 gateway kernel: hda: ST340016A, 38166MB w/2048kB Cache, CHS=4865/255/63
Jan 26 12:56:15 gateway kernel: hdb: ST340016A, 8063MB w/2048kB Cache, CHS=1027/255/63
Note that both drives are identical model numbers.
I will have to down the box and determine exactly _what_ the BIOS thinks it is doing.
Hmmm. The plot thickens.
Sean