Hi Charlie, many thanks for the reply.
I formated the first partition of the drive so the tables look like:
Disk /dev/sda: 2000.3 GB, 2000398934016 bytes
255 heads, 63 sectors/track, 243201 cylinders
Units = cylinders of 16065 * 512 = 8225280 bytes
   Device Boot      Start         End      Blocks   Id  System
/dev/sda1   *           1          13      104391   fd  Linux raid autodetect
Disk /dev/sdb: 250.0 GB, 250059350016 bytes
255 heads, 63 sectors/track, 30401 cylinders
Units = cylinders of 16065 * 512 = 8225280 bytes
   Device Boot      Start         End      Blocks   Id  System
/dev/sdb1   *           1          13      104391   fd  Linux raid autodetect
/dev/sdb2              14       30401   244091610   fd  Linux raid autodetect
Then added to the array:mdadm --add /dev/md1 /dev/sda1
Which sync'd up in no time.  (only 100M I suppose)  but now I don't know how to partition the rest of the drive.  Should I create the next partition to be the same size as the old drive or should I maximise the space before adding to the array?
Thanks again,
N