Lost mdadm RAID6 array and tried everything, hoping for any other suggestions you may have

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Hello,

I've had very good luck with mdadm RAID1 over the years and it's really helped out. More recently I got a bit more adventurous and tried out RAID6, but after my recent experience with it I'm considering writing my take on "RAID6 considered dangerous" :)

Quick summary:

* Slackware 64 13.37, Linux 2.6.37.6, on Shuttle XPC 4gb ram

* RAID6 array, 8 active drives in a chassis connected via 2 esata cables to a shuttle pc, 12TB total, worked fine for several months. Esata controller w/port multiplier support.

* Couple of days back, noticed array was down, with second half of the drives shown as down. Assumption - 1 cable or esata controller port hickuped, taking 4 drives out of the array,
   or something happened due to the hot temps that day

* /proc/mdstat showed (S) next to some (or all, can't remember) of the drives in the array - I think that means spare, but I had no spares defined for the array so it seemed weird

* Rebooted machine and checked smartctl status, all 8 drives in chassis showed OK status, and they were all accessible using gdisk and fd00 partitions appeared fine.

* Tried to reassemble normally, then with force, nothing happened - no errors, array just didn't come up. Did not try --assume-clean (to my regret). Maybe would have worked,
   will never know.

* Took some internet advice and tried --create to recreate the array, however I forgot which chunk size I used so I tried several times with different chunk sizes (some resync took place each time). Could not find any info on Internet about whether the resyncs blew away my data.

* After each mdadm array recreate, tried to mount the array but failed with missing superblock

* dd'd a few gb's from the array and tried to grep text in a failed attempt to determine chunk size

* Tried testdisk utility to attempt to locate file system structures after recreating array with various chunk sizes, didn't let utility finish but it didn't seem to be doing anything useful

* R-Studio - tried using it, didn't seem it would do anything useful for me

At this point the key questions I'm aware of:

* Did recreating array with various chunk sizes blow away my data/file system structures
  (I did not use --assume-clean when recreating array)

* If the data is still ok, is there a way to determine the chunk size that was used? I'm hoping the metadata version and bitmap options used would not affect being able to recover the array, because I don't remember which metadata and bitmap options I used if any.

* Given the correct chunk size, if I recreate the array, is there some way to convince mount to mount the array, or some way of fixing the ext4 structure, or any other way to get the data of the array other than the file carving utilities that dump everything in a bunch of random
   directories.

I'm well aware RAID != backups and I had a backup but it was a few months old unfortunately. I didn't expect at all this failure mode of having half the disks disappear and having the array be so hard to recover. Most of the Internet information is focused on array creation and mgmt, and I found precious little information on recovery, some of which was wrong and dangerous. At this point I do consider RAID6 to be dangerous and will avoid it where possible. It just makes recovery so much harder when the file system and data is broken up into little pieces.

Thanks in advance for any tips.

Regards,
--Ed
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