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