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Just in case soeone gets into the same position that I was. FDISK did eventually become my froend - still not sure why the advice was so enigmatic.
My problem:
WHen creating a partition on my new 1Tb Seagate drive openSUSE YAST created a partition of size 953.50Gb when I set it to create the maximum partition. Previousely it had created partitions of 953.51Gb on 4 1Tb WD drives I had bought so when I tried to add this new device to the array I received:
mdadm: /dev/sdc1 not large enough to join array
My solution:
Running fdisk -l gave me:
The first entry repeated 4 times for each of the raid devices
Disk /dev/sdb: 1000.2 GB, 1000204886016 bytes
255 heads, 63 sectors/track, 121601 cylinders
Units = cylinders of 16065 * 512 = 8225280 bytes
Disk identifier: 0x000655ae
Device Boot Start End Blocks Id System
/dev/sdb1 1 121601 976760001 fd Linux raid autodetect
and this for the new device:
Disk /dev/sdc: 1000.2 GB, 1000204886016 bytes
255 heads, 63 sectors/track, 121601 cylinders
Units = cylinders of 16065 * 512 = 8225280 bytes
Disk identifier: 0x000b7001
Device Boot Start End Blocks Id System
/dev/sdc1 2 121601 976752000 fd Linux raid autodetect
Saw the starting in Cylcinder 2 and thought I'd manually create the device in YAST rather than just setting it to max. Unfortunately YAST/partitioner refused toallow parameters 1 -> 122601.
So decided use my new best friend :
# fdisk /dev/sdc
The number of cylinders for this disk is set to 121601.
There is nothing wrong with that, but this is larger than 1024,
and could in certain setups cause problems with:
1) software that runs at boot time (e.g., old versions of LILO)
2) booting and partitioning software from other OSs
(e.g., DOS FDISK, OS/2 FDISK)
Command (m for help): p
Disk /dev/sdc: 1000.2 GB, 1000204886016 bytes
255 heads, 63 sectors/track, 121601 cylinders
Units = cylinders of 16065 * 512 = 8225280 bytes
Disk identifier: 0x000b7001
Device Boot Start End Blocks Id System
Command (m for help): n
Command action
e extended
p primary partition (1-4)
p
Partition number (1-4): 1
First cylinder (1-121601, default 1): 1
Last cylinder, +cylinders or +size{K,M,G} (1-121601, default 121601): 121601
Command (m for help): t
Selected partition 1
Hex code (type L to list codes): fd
Changed system type of partition 1 to fd (Linux raid autodetect)
Command (m for help): w
The partition table has been altered!
Calling ioctl() to re-read partition table.
Syncing disks.
Then it showed in partitioner as 953.51Gb - all was ok with the world.
(just to finish off the raid expand:
# mdadm /dev/md1 -a /dev/sdc1
mdadm: added /dev/sdc1
# mdadm --grow /dev/md1 --raid-devices=5
mdadm: Need to backup 1536K of critical section..
mdadm: ... critical section passed.
.... and the long wait starts
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