There is already data written on this disks.
... that's a problem. mkfs will overwrite that data. Good thing it didn't work.
#mkfs -t ext3 /dev/md0
mkfs.ext3: Device size reported to be zero
... looks like you need to add the drives to md0.
# cat /proc/mdstat
... explicitly remove anything that shouldn't be there. (mdadmin -r)
This is just md0 of a RAID1 that is being rebuilt right? You want to mirror partitions on the existing drive to the new one and their geometery is identical and everything?
So the trick is to try adding the mirror partitions like normal:
$ sudo mdadm -a /dev/md0 /dev/sda1
$ sudo mdadm -a /dev/md0 /dev/sdb1
$ sudo mdadm -a /dev/md1 /dev/sdb2
... etc
http://www.heronforge.net/redhat/node14.html