Linux - HardwareThis forum is for Hardware issues.
Having trouble installing a piece of hardware? Want to know if that peripheral is compatible with Linux?
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You need to use raidhotadd to add the new drive to the set. Once this is done it will start to rebuild sliently in background. You'll need to create the necessary partitions before you add the drive. I would suggest you have a look at http://www.tldp.org/HOWTO/Software-RAID-HOWTO-6.html the HOWTO is a little old but still useful.
Uhm... Thats rather odd. I was going to suggest that you check the remaining drive to see how big the partition is, and create one of the same size on the new disk. What command are you using to start fdisk?