you can download a text file of the output from pvdisplay and other commands here http://www.tdb.com.au/dl/raid.txt
Any suggestions, should I try add another drive or have I missed some important step?
Nope the partition seems good as i see, only md2 is concerned by the spare drive however it is what i expected. No i think that you can add all other drives.
If you have time you can add them one after one, but it could work if you add them all in one time, except that you may have a bigger risk to loose your data
, yes adding a drive to a raid is not without risks. Eventually you can make a backup of drive as explained in documentation, but you need a large array.
The process can take many hours or even days. There is a critical section at start, which cannot be backed up. To allow recovery after unexpected power failure, an additional option --backup-file= can be specified. Make sure this file is on a different disk or it defeats the purpose.
mdadm --grow --raid-devices=5 --backup-file=/root/grow_md1.bak /dev/md1
mdadm --grow --raid-devices=4 --backup-file=/root/grow_md2.bak /dev/md2
If you have some troubles to add a drive to an array, you should try to erase the mbr, or the whole drive with the dd command
#dd if=/dev/zero of=/dev/sdX bs=512 count=1
If i say that it is because in the first attempt you were not be able to reshape the array with 9 drives and i suspect that one of them could make some noise when you want to use it.