Just to scare you and hijack the thread:
-bash-3.00$ md5sum /home/e-smith/files/ibays/install/files/OS/XP/WindowsXP-KB835935-SP2-ENU.exe;
a3698937beffb3e6fda0ff4f9eac7947 /home/e-smith/files/ibays/install/files/OS/XP/WindowsXP-KB835935-SP2-ENU.exe
-bash-3.00$ md5sum /home/e-smith/files/ibays/install/files/OS/XP/WindowsXP-KB835935-SP2-ENU.exe;
702ac77029cc728cdb66f56566ee4a1c /home/e-smith/files/ibays/install/files/OS/XP/WindowsXP-KB835935-SP2-ENU.exe
Any file over ~ 200MB on my system gets corrupted. It's not RAM. I suppose it could be other hardware, but if I drop the RAID and use either drive in single mode -- same hardware -- it's perfect.
Weird eh? I can't find any known bugs on the forum so I guess it's just me!
To answer your questions:
1. In the mdstat the raid 1 shows sdb2[1] sda2[0] I replaced /sdb, so I assumed sdb should be listed second here instead of first. Does the sda[0] mean the drive thats R/W and sdb[1] mean RO?
I DON'T KNOW!! But! I don't think the order is relevant, and what gives you the idea that mirrored disks have one R/W and one R/O? That makes no sense to me, where did you get that idea?
2. If I replace /dev/sda now will it build from a synced sdb the same way sdb syned with sda?
It can do, yes -- I used
mdadm --add /dev/md1 /dev/sda1
then
mdadm --add /dev/md2 /dev/sda2
When I replaced sda.
3. If I add a third 1tb drive as a hotspare, will the raid automatically add it or will I have to do command line functions to add it as a hot spare? Is there a real advantage to having a Raid1 + hotspare?
The advantage is that you're proteced if the second drive dies while you're still out buying a replacement for he first. Not really very likely.
You would have to configure it as a hot spare, try
man mdadm
for details.
Whether or not it's worth having a hot spare depends on what the server is used for.