Well, I went ahead and tried the forced assembly: bill@bill-desk:~$ sudo mdadm --assemble --force /dev/md1 /dev/sdg1 /dev/sdh1 /dev/sdi1 [sudo] password for bill: mdadm: Merging with already-assembled /dev/md/1 mdadm: Marking array /dev/md/1 as 'clean' mdadm: failed to RUN_ARRAY /dev/md/1: Input/output error (The drive letters have changed because I removed a bunch of other drives. The original drives are now on sd[b,c,d,e] and the copies are on sd[f,g,h,i] with sdf being a copy of the presumably bad sdb with the event count which doesn't agree with the other 3 disks.) So, it failed. dmesg shows: 152144.483755] md: array md1 already has disks! [152144.483772] md: kicking non-fresh sdb1 from array! [152144.520313] md/raid:md1: not clean -- starting background reconstruction [152144.520345] md/raid:md1: device sdd1 operational as raid disk 2 [152144.520346] md/raid:md1: device sde1 operational as raid disk 1 [152144.520348] md/raid:md1: device sdc1 operational as raid disk 3 [152144.522219] md/raid:md1: cannot start dirty degraded array. [152144.566782] md/raid:md1: failed to run raid set. [152144.566785] md: pers->run() failed ... [152144.568169] md1: ADD_NEW_DISK not supported [152144.569894] md1: ADD_NEW_DISK not supported [152144.571498] md1: ADD_NEW_DISK not supported [152144.573964] md1: ADD_NEW_DISK not supported mdstat shows sdb no longer part of the array: bill@bill-desk:~$ cat /proc/mdstat Personalities : [linear] [multipath] [raid0] [raid1] [raid6] [raid5] [raid4] [raid10] md1 : inactive sdd1[2] sde1[1] sdc1[4] 11720653824 blocks super 1.2 details of the array: ill@bill-desk:~$ sudo mdadm -D /dev/md1 /dev/md1: Version : 1.2 Creation Time : Tue Sep 25 23:31:31 2018 Raid Level : raid5 Used Dev Size : 18446744073709551615 Raid Devices : 4 Total Devices : 3 Persistence : Superblock is persistent Update Time : Sat Jan 4 16:52:59 2020 State : active, FAILED, Not Started Active Devices : 3 Working Devices : 3 Failed Devices : 0 Spare Devices : 0 Layout : left-symmetric Chunk Size : 64K Consistency Policy : unknown Name : bill-desk:1 (local to host bill-desk) UUID : 723f939b:62b73a3e:e86e1fe1:e37131dc Events : 38643 Number Major Minor RaidDevice State - 0 0 0 removed - 0 0 1 removed - 0 0 2 removed - 0 0 3 removed - 8 65 1 sync /dev/sde1 - 8 49 2 sync /dev/sdd1 - 8 33 3 sync /dev/sdc1 Now if I try the forced assemble again I get: ill@bill-desk:~$ sudo mdadm --assemble --force /dev/md1 /dev/sdg1 /dev/sdh1 /dev/sdi1 mdadm: Found some drive for an array that is already active: /dev/md/1 mdadm: giving up. I'm lost now. Not sure what to do anymore. Do I need to edit mdadm.conf? Do I need to remove the original drives? Any ideas Wols? Bill