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Red balled drive - ran reiserfsck now shows as unformatted help! ESXi Unraid B14

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Specs:

i7 920 Intel CPU

ASUS Rampge III Extreme

ESXi 5

24GB DDR3

Virtualized UNRAID Pro Beta 14 (Upgrade time, I know)

Supermicro SASLP 8 port card passed through via VT-D

Corsair TX750W

ATI 5450 GPU

ATI 5450 GPU - VTD passed through for Win8 virtualized HTPC

320GBx4 (2.5") and 1TB (WD Black) for VM Storage

 

UNRAID Array

Parity - 2TB

Storage - 2TBx3 and 1.5TBx2

Cache - 500GB WD Blue 7200

 

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History:

Two weeks ago from Wednesday my weekly parity check had some insane amount of errors but it corrected them all.

I thought it was odd so I kicked off a few more parity checks that week and everything was fine. No errors

 

One week ago from Wednesday I tried to access my array the following day after my weekly parity check and I couldn't access it at all. I couldn't telnet in, the console on esxi also was locked up.

My other VMs were working just fine so I figured unraid had crashed. Against my better judgement I rebooted the VM.

It started a parity check and it passed.

 

This past Wednesday my parity check ran and my array was up so I didn't think anything of it. I logged in to check and saw one of my drives was redballed. At this point I kind of freaked out. I had recently gotten a new hotswap enclosure (Norco 5 in 3) in addition to my two iStarUSA 3in2's. So I stopped the array and moved the drive into one of the iStarUSA's to see if it was just a bad slot on the Norco or something.

 

When I popped the drive back in, I went into the array, selected no device for Disk 3 (the disk in question) and started the array. Then I stopped the array and selected the disk again. It turned blue and started copying data back from Parity. It got to about 15% and then my whole ESXi box locked up. In the 4-5+ months I've had this setup I've never seen this happen.

 

I had to hard reboot the whole system. Once everything came back up I shut down the whole ESXi setup and rebooted and ran memtest. Everything passed after 5 passes. I checked my power supply rails with everything on, they were at 12.01V and 5.02V.

 

So yesterday I ran a reiserfsck check on md3 (disk3) in maintenance mode and it came back and said it had 3 errors. I then the reiserfsck fix-fixable. It corrected 3 errors. At the same time it said it was copying data from parity to re-build the drive. Once that finished I stopped the array which was in maint mode. I started it in normal mode and it now says that disk 3 is "unformatted". I am not sure what to do now because I am afraid of losing data. It had 1TB out ofT 2TB.

 

For the sake of troubleshooting I can move my unraid into its own machine. I have a spare build I could put it on. I have syslogs from each events if anyone would like them. Please just tell me where you'd like me to put them. (Pastebin or locally via attachments)

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