New drive not able to be added to array, i/o error after preclear/rebuild

troubleshooting steps here: https://forums.unraid.net/topic/193192-new-drive-giving-errors-after-preclear-no-smart-issues/

first attempt, standard pre-clear (skipped pre and post read), added to array. The moment I tried to write to it, it disabled the drive with "unraidd7: attempt to access beyond end of device" errors

ran smart tests, everything was fine, so I rebuilt the drive onto itself, as soon as the rebuild completed, it failed the same way again.

Upgraded to the latest beta, removed the drive, shrunk the array. Then did a full pre-clear on the drive again. 0 errors on the drive during the 2 day task. Added it to the array again and once the rebuild completed, got the same errors and the drive was disabled:

Sep 7 04:30:21 Homer kernel: md: disk7 read error, sector=24

Sep 7 04:30:21 Homer kernel: unraidd7: attempt to access beyond end of device

Sep 7 04:30:21 Homer kernel: sdk: rw=1, sector=88, nr_sectors = 8 limit=0

I'm going to downgrade to 7.0.1 and see if that helps.

homer-diagnostics-20250907-0918.zip