I'm finally doing the reiserfs to xfs conversion following these instructions. I copied everything from the first disk I was converting to an external hard drive, stopped the array, changed that disk's file system to xfs, started the array, and formatted that one disk. Everything started and looked good and I copied all the data back. Then I started the process on the next disk, copying everything to the external hard drive again. But this time when I stopped the array, I get a message saying "Replacement Disk is Too Small" for that first disk I converted and can't start my array. Some searching pointed me to the Tools -> New Config tool, is this what I should try? Thanks for any help!

From what you said you are not doing a replacement so that message does not make sense.

 

You are likely to get more informed feedback if you attach your system's diagnostics zip file to your next post in this thread.  
It is always a good idea to do this to allow us to see the current state of your system and so we can see logs.

Sure thing, attached logschow-server-diagnostics-20250409-0648.zip

This is the result of a bug, and it happened because you are still using unaligned partitions, this has been fixed a long time ago, problem is that you are still running an old release, you should be able to fix it by doing the following:

 

Since disk4 is also unaligned and the same capacity, we should be able to use that MBR to restore the correct partition layout for disk4, so first backup the current disk3 MBR, just in case:

 

dd if=/dev/sdY of=/boot/disk3.mbr bs=512 count=1

 

Replace Y with the correct disk3 identifier, as of last diags it was /dev/sde

 

Now copy disk4 MBR to disk3:

 

dd if=/dev/sdX of=/dev/sdY bs=512 count=1

 

Replace X with disk4 letter, Y with disk3, as of last diags they were /dev/sdf and /dev/sde respectively, but check because they can change, double check again you are using the correct command, dd can be dangerous.

 

This will take just a second, once it's done reboot and post new diags after array start, assuming it starts, and it should.

 

If you are not sure how to do the above or are not comfortable suing the CLI, you can alternatively rebuild the disk, that should also resolve the problem, though it will require a full-disk rebuild.

 

In any case, once this is resolved, make sure to upgrade to latest stable 6.12, or 7.0, or it will happen again with the other disks.

 

 

 

 

 

Thank you so much, tchow-server-diagnostics-20250409-0848.ziphat worked!

Looks good, don't forget to update before converting the next disk, or it will happen again.