Raid problem. Big big OOPS!

Asus white box amd athelo... / Home grown
April 18, 2009 at 23:36:27
Specs: Linux x86_64
Have a raid 5 consisting of four WD 400Gb Drives. Drives are SATA.
Mother Board is ASUS AMD dual Athleon-64.
A drive started reporting problems. Soon it failed.
I removed it and the RAID ran on three drives just fine.
I ordered a new 400 GB WD on EBay & sent my old drive to WD who replaced it with a new 500GB drive.
Meantime the new 400GB arrived. I installed it and it setup just fine except couldn't get in into the RAID array. Soon I had more drive reports of impending doom.
Ordered five 750GB drives a new mother board and built a new system to do a back up to. This took a couple weeks but as Murphy's law goes just as I was hooking cables to the two machines for the backup I heard that awful HD click as the failing system dropped the power supply. Wasn't touching it so I don't know what happened. I rebooted to a failed RAID and found that my RAID was only two drives, not three as I thought and the system will/would not boot.
The second drive now can't be accessed by anything but FDISK.
No I didn't write any changes just did a:
FDISK /DEV/SDB and the P. Followed by Q.
I did this by booting to a live DVD version of Fedora Core-7. The same version as the failed system.

It shows "partition does not end on Cylinder boundary for the first two partitions. There are only three.

I now have built a new system on a new drive in this box. The three RAID drives are still in the box but disconnected.
Is there any way to fix the partitions of this drive without destroying the data???
Should I hook up the offending drive to this new system, "Fedora Core 10" running on a single 500Gb drive?
Guess where that drive came from?
Is there a partition program to fix this without or with minimal loss?
Recovery software etc.

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April 19, 2009 at 11:57:20
Look at the link below for information on Western Digital Enterprise level hard drives. Immediately below is an excerpt from the link. This is one of the most common reason for RAID array failure. Those drives may actually still be good. Just not up to the RAID 5 needs.

“RAID-specific, time-limited error recovery (TLER) - Prevents drive fallout caused by the extended hard drive error-recovery processes common to desktop drives”.

For info on all WD enterprise drives look at the link below.

I don't know of any way to get the array working or to save any data. As you know the data is distributed across the whole array with some fault tolerance. You have exceeded the fault tolerance.

Hope some one else can give you better news.

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