Thanks for the prompt on the rebuild I tracked down the instructions you were referring to and they were much better than the SME how to I had.
Yes that is the drive geomentry as reported by fdisk. However in the bios the units have identical H,C,S figures. I have determined that the Maxstor 20GB drive is slightly smaller than the Quantum one.
I have given up on getting this disk into the array. I moved the files from the Ibays to a PC. Then did a backup to desktop.
I tried a fresh install of SME 5.1.2 this caused more issues. If either drive is installed and software raid is not chosen the install goes ok. I have 19GB of available disk space. Now if both drives are back in the server and I install SME as software raid I only get 9GB of disk space and on boot an error message saying something about the mirrored partitions being on the same HDD. I can also replicate this problem under SME 5.6. If I do a standard RH 7.3 install it picks up that the drive geomentry of the Maxtor may not be being recognised correctly and gives a warning message.
To further compound the problem the restore from desktop fails with out an error message. The system could not display the updated web page following pressing the restore button. I tried this three times by then it was 2am in the morning

.
I am now off to by two new identical HDD ( At least I can now upgrade the drives to 60GB models) and will try rebuilding the server tonight.
I am now wondering if SME 5.6 will support my highpoint IDE raid controller. I removed it from the server as I could not get previous versions of SME to install on it. If I can get the highpoint controller to work I can then drop the software raid.
Thanks for your suggestion
Regards
Mike Drummond