Thanks.  After playing with it I figured out I'd still have an md 
superblock for the mirrored array on my disk.  I was hoping I could 
accomplish everything without taking it offline -- I guess not.

P.S. - In case anyone is following along; I'm actually booting from a 
separate mirrored boot partition (/boot).  The RAID5 array holds /, 
/var, and /home.  I won't need to make any changes in GRUB since I'm 
leaving that array alone.  The last I heard, you can't boot from RAID5.

Sidney Cammeresi wrote:
> On Thu, 11 Jan 2007 at 06.35.40 -0600, Dave Alitz wrote:
>   
>> I'm starting with 4 drives.  Two active in the current mirror and two 
>> unused. The process I'm considering:
>>
>>     Fail and remove a drive from the current md mirror, leaving three 
>> unused drives
>>     Create a new RAID5 array
>>     Add the new md RAID5 device as a member of the degraded mirror
>>     
>
> RAID1 doesn't work the way you think it does.  You'll end up with a
> degraded RAID1 made from a RAID5.  It will work though.
>
> I recommend creating a degraded RAID5 from your two unused disks and
> doing a copy to the new array.  After the data are copied, fail one disk
> out of the old array and add it to the new array, which will cause parity
> to be computed.  After that's done, nuke the old array and add the last
> disk to the new array as a hot spare.
>
> This way, you end up with one array composed of physical disks, and your
> data are always in two places throughout the process.
>
>