bootsect replicated in p1, RAID enclosure suggestions?

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Hello all,

So I have an Intel NUC (for low power Linux) plugged via USB into a 4
bay enclosure doing linear (yeah I know; it's the backup server, the
primary is raid10).

And every once in a while, this happens (*see end).  The partition 1
that would normally contain a MD slice ends up being a replica of the
boot cylinder.  I can't tell if it's the mdraid linear impl, the
kernel doing something weird, the USB drivers, the enclosure firmware,
or what.

Anyway, this happened while I was restoring a Windows machine whose
root drive suddenly took a nosedive, and it happens every 6 months
or so.  Today it happened while I was in the middle of recovering
a Windows machine whose 1TB SSD threw up on C: and totally nuked
the data.

The last low-power option I tried was an OpenRD Ultimate based around
ARMv5TE which was basically unsupported by debian by the time I got
it, and subsequently became ultra-flaky due to what seemed to be RAM
problems - it was crashing every 3 days with kernel panics, and every
once in a while would do something worse.

Any recommendations on a low power hardware with a well-supported
distro, that matches up well with a real backplane and SATA
connections instead of USB.  The only caveat is that I want to encrypt
raw disks and it has to not be very noisy - so no rackmount gear
with 65dB 1" dog whistle fans.  Obviously, whatever backplane must
be well-supported by the distro.

Also, does anyone have experience with cryptsetup on multiple
partitions?  I can do that but get prompted multiple times and I was
wondering if anyone knew an easy way to fix the boot time scripts to
avoid that, only prompting once per unique underlying crypttab.

And finally, I have a story about buggy drive firmware that you
might enjoy, especially if you were doing this sort of stuff in
the 90s as well.  Cheers:

http://www.subspacefield.org/security/hard_drives_of_doom/


[*]

# parted /dev/sde
GNU Parted 2.3
Using /dev/sde
Welcome to GNU Parted! Type 'help' to view a list of commands.
(parted) p                                                                
Model: WDC WD40 EFRX-68WT0N0 (scsi)
Disk /dev/sde: 4001GB
Sector size (logical/physical): 512B/512B
Partition Table: gpt

Number  Start   End     Size    File system  Name        Flags
 1      1049kB  4001GB  4001GB               Linux RAID  raid

(parted) q                                                                
# parted /dev/sdd1
GNU Parted 2.3
Using /dev/sdd1
Welcome to GNU Parted! Type 'help' to view a list of commands.
(parted) p                                                                
Model: Unknown (unknown)
Disk /dev/sdd1: 4001GB
Sector size (logical/physical): 512B/512B
Partition Table: gpt

Number  Start   End     Size    File system  Name        Flags
 1      1049kB  4001GB  4001GB               Linux RAID  raid

-- 
http://www.subspacefield.org/~travis/ | if spammer then john@xxxxxxxxxxxxxxxxx
"Computer crime, the glamor crime of the 1970s, will become in the
1980s one of the greatest sources of preventable business loss."
John M. Carroll, "Computer Security", first edition cover flap, 1977
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