Robj, I didn't CHANGE the file system, it became an XFS drive only after I formatted it. I popped the replacement drive in right from the new WD box it came in. I ran the preclear script and when it passed I tried to assign it and here is where it gets fuzzy. I seem to recall that it would not allow me to assign the drive without formatting it first. That's when I chose XFS. The format completed and I assigned the drive and started the rebuild. At no point did any message or warning come up saying that what I was doing might be destructive. That's the thing that disappoints me. I had no clue that I was deleting a whole drive full of data.
I'm in the tech biz myself and the steps I did seemed rather logical: take out a drive, pop in a new one, test it, format it, and start a rebuild. I suppose the format part is how I screwed up but in my experience with every OS I've worked with, a drive has to be formatted to be of any use.