I have a Compaq Proliant Server with two 148GB SCSI hotswap drives - when I set up the SME, I told it to do Raid 1.
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Thanks,
Chris Buechler
Hi Chris (are you the same Chris Buechler involved in m0n0wall development?

)
follow this steps:
a) I've notice your raid is working in degraded mode, ad sdb2 partition in md1 device is not used..
so, try to do this:
mdadm -a /dev/md1 /dev/sdb2
array rebuilding and synchronization will start and will took a long time (it depends on hd size and rebuilding speed that is abount 10 mb/s in standard sme installation); if everything is ok after array recostruction than your sdb scsi hd is ok..
in any case, smartmontools use is recommended to check the health status
of your hd
b) now, if hd is ok, you can run raidmonitor -iv to save your raid configuratione; if not.. not a real problem

c) do (Iguess you want to change sdb hd)
mdadm -r /dev/md0 /dev/sdb1
mdadm -r /dev/md1 /dev/sdb2
mdadm -r /dev/md2 /dev/sdb3
after this, you can safely remove sdb.. You say it's a hotswap hd, so a shutdown should not be necessary
d) insert your new hd
if you have run successfully raidmonitor (see above), follow dmay help
if not, do
sfdisk /dev/sda -O hdd-partition-sectors.save
sfdisk /dev/sdb -I hdd-partition-sectors.save
or manually run fdisk on /dev/sdb
after partitioning the new hd, you can do
mdadm -a /dev/md0 /dev/sdb1
mdadm -a /dev/md1 /dev/sdb2
mdadm -a /dev/md2 /dev/sdb3
et voilĂ ..

well.. I hope you are wise enough to backup your data BEFORE following my instructions

HTH
Ciao
Stefano