RAID1 rebuild fails due to disk errors

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http://serverfault.com – Quick info: Dell R410 with 2x500GB drives in RAID1 on H700 Adapter Recently one of drives in RAID1 array on server failed, lets call it Drive 0. RAID controller marked it as fault and put it offline. I replaced faulty disk with new one (same series and manufacturer, just bigger) and configured new disk as hot spare. Rebuild from Drive1 started immediately and after 1.5 hour I got message that Drive 1 failed. Server was unresponsive (kernel panic) and required reboot. Given that half hour before this error rebuild was at about 40%, I estimated that new drive is not in sync yet and tried to re (HowTos)