Morning!
So good news/Bad news scenario. Since my server was stupidly unstable. I have yanked the SATA controller ( sil 3114 on the compatible hardware list) , and setup the raid again, minus the drives that were on the controller, Lucky for me no data had made it onto any of them yet.
This problem does seem localised to the sil 3114, Although to help rule it out, I'm going to put this into a friends unraid server, and see if we can get it to fault. Im also going to use his super micro 8 port card in my server, to see if i can get it to fail. As I get what was said above, that it should be a hardware ( say mobo/chipset ) error being masked by something else, I would like to single it out as the card if it is the problem.
On that, with a quick look on google, im not the only one that's had issues with the card. Sometimes a bios update to the motherboard or card fixed it, sometimes it didn't.
For me, the updated firmware on the sata device, only made problems worse! not better. and the legacy firmware wouldnt allow my system to boot ( although it was from 2003 or something.. So im not surprised.)
I appreciate the assistance!