I run into exactly the same problem, but the weird thing is that it worked perfectly for about two weeks. After two weeks and 10 min, (were the last ten minutes was the time it took my client to give me final approval for some major online work.) I could no longer collect or copy my media. Sure I had backups, but it would had taken days of tedious work get everything back in order. Since I had nothing to lose, I used the migration function to change the raid from 128k to 64k block size without reformat. This took about 40 hours or so. Now my raid is working perfectly again and all media seems to have survived the migration. The info in your post saved me a major headache and about a week of work. Thank you very much!