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Problem with Flash drive while swapping failed disk

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Hi all,

 

Something very strange seems to have happened to one of my unraid installs. I'll describe the set of circumstances as best I can and would really appreciate any advice as it's a real head-scratcher!

 

- One of my drives failed, red ball. Because I have limited bays in the case, I disabled the drive from the array, removed and installed a replacement drive

- Brought the array online, one disk missing so using parity to fill in

- Started a pre-clear on the new drive to make sure it's good

- unmenu stopped responding at some point during the pre-clear as did airvideo so I telnetted in to kill any errant processes and restart them

- I now notice that the /boot folder is completely empty, no kernel, no config directory, no unmenu directory

- The array is still up, the pre-clear finished fine

- There are lots of errors in the syslog like this: Media kernel: FAT: Directory bread(block 2591199) failed, which leads me to conclude the Flash drive has become unreadable.

 

So.. If I stop the array and reboot, and the config/super.dat file has been lost, presumably I will lose the data on the disabled drive?

 

If so, it seems like I should format the newly pre-cleared drive as a normal data disk and mirror all the files from the failed disk to this before I shut down? Then I can boot from a new usb key and at least have all of my files intact?

 

As I say, any advice appreciated. I won't do anything until I have a clear plan.

 

Many thanks in advance!

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