Originally Posted by r00tb00t
Has anyone got any ideas? It is a hardware raid if this makes a difference, would a software raid solve the issue, I have never used one before?
No, RAID has nothing to do with file system limitations, Software or Hardware based. Keep your hardware RAID, software RAID sucks.
What filesystem are you formatting this in? So when you're doing a custom disk layout, are you actually seeing a clean blank slate of drive space, no existing partitions leftover? Also, you may want to consider creating at least:
LVM that includes a separate /, /usr, /var, /tmp and /home. Also, if this is for backups, might want to create a separate /backup or /storage directory and allocate most of the space to it, don't put it in home, home is for user home directories, nothing more and nothing less.
Be conservative too, / takes up literally zero amounts of space when you partition out /usr and /home from it. And with LVM, you can leave some empty unused space to grow partitions when needed or max it out and grow/decrease where needed when the time comes.
A possible good layout to start with:
/boot = 100MB
swap = Match Installed RAM Size
/ = 1024MB
/usr = 8196MB
/var = 4096
/tmp = 4096
/home = 4096
/backup = Remaining or a TB, you're call, I don't know how much you've got to backup to start with.