Can't rebuild mirror on Windows 2003, Event ID 7,29

I have an old HP Proliant G3 server. It has two SCSI 68 pin Ultra320 drives.
Yesterday one drive (secondary plex) failed. But rebuilding process always fails at 99%. This what I have done so far.

1.  I replaced the drive, rebooted
2. Opened Disk Management console, I see three drives, 1 source drive, 1 failed,missing drive, 1 new drive.
3. I right-clicked on the failed drive and removed mirror.
4. I right-clicked on the source drive, then selected 'Add Mirrror' with the new drive.
5. Resynching goes to 99%, then failed and the new drive returns to 'unallocated'.
6. I tried to change disk type to basic, then to dynamic back, tried to change between MBR, GPT, no luck.

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In event viewer, it has event ID 7;
The device, \Device\Harddisk0, has a bad block.

Event ID 29
dmio: Harddisk0 read error at block 62841151: status 0xc000009c
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Does it mean it's source drive or the new drive?  

On each drive property, it shows as;
source drive: Bus number 0, TargetID 0
new drive: Bus number 0, TargetID 1.
LVL 1
crcsupportAsked:
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JohnBusiness Consultant (Owner)Commented:
The device, \Device\Harddisk0, has a bad block.
Does it mean it's source drive or the new drive?  


If HD0 is old and HD1 is the new drive, it means the source drive is the problem.

Have you a complete backup?
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Fred McLeanSystems EngineerCommented:
Is the Raid 1 configured using Windows Disk Management? Or Are you using HP Raid Array Management?
If your using Windows Disk management - you can't use "Basic" needs to be "Dynamic" discs to configure RAID.

I always use the HP Proliant Raid Array Management tools - to build any RAID configurations.
G3 Server is fairly old - If you have the original HP Proliant discs you may be able to load the drivers and management tools, However, that may cause you to rebuild the whole system - Make sure you have a good  backup.
If you have the HP Smart Start CD's for the HP Prolaint G3 System, you can use that to build and configure the system properly.
Remove the "Windows" management of creating RAID. HP does a better job providing RAID for the G3 System. Takes Microsoft Windows out of having to manage the drive Array - leave that to the manufacturer (HP).
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crcsupportAuthor Commented:
Yes, I did backups. I have to find a way to finish rebuilding mirroring, but now I can't rebuild, it seems as the bad block on source drive blocking the mirroring.
I am reluctant to run chkdks /r against source drive because I had bad experience before, not with this server, but with other  proliant server. When I do chkdks on system drive, it fails to boot.

Anyone knows a trick to finish rebuilding mirror(windows software mirror) without chkdisk /r on source drive?
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crcsupportAuthor Commented:
Fred, it's on Windows mirrroing on dynamic disk.
Whoever built this sever, installed on a single drive and did all the job. When I took over, I found system runs on single drive instead of mirrored. So I had no choice, but put software mirror. If I use the adaptec controller mirroring, it should erase the system, but I think it's not an option here. I have to put back to successful software mirroring.
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JohnBusiness Consultant (Owner)Commented:
In answer to your question, if there is a bad block on HD0, I do not know of any way to complete the mirror.
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crcsupportAuthor Commented:
I think so..damn..trouble
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crcsupportAuthor Commented:
maybe I wait a few day more until any genius steps in to give some comments..
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Fred McLeanSystems EngineerCommented:
You may want to review these two articles:

Windows 2003 - RAID 1 Configuring...

http://support.microsoft.com/kb/323432

Troubleshooting RAID -
http://support.microsoft.com/kb/120227

I would also look at the HP quick Specs for the Proliant server you have. Verify the Storage Adapter is the generic
Storage card for the server and look at the specifications of support. Example:
Google: "ML350 G3 quickspecs"
returns this link with help info on this HP G3 Server:
http://www8.hp.com/h20195/v2/GetDocument.aspx?docname=c04286456

Sounds like you inherited a problem that may take time to resolve.
If the Storage Controller is not the generic HP Storage card - you may need to refer to the "Adaptec" manufacturer web site for updated Windows drivers and support info.
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crcsupportAuthor Commented:
It's genuine HP scsi controller.
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crcsupportAuthor Commented:
It seems like running chkdsk /r finds bad sectors only and reallocate. When I do this, it doesn't prompt to reboot system. So I will try this
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crcsupportAuthor Commented:
I'm in the middle of rebuilding mirror, but I think it will fail;
http://support.microsoft.com/kb/325615/en-us
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crcsupportAuthor Commented:
failed...........ah!!! Now only option is to move all apps to another server.
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JohnBusiness Consultant (Owner)Commented:
Yes. That bad block on the source drive was non-recoverable.
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JohnBusiness Consultant (Owner)Commented:
@crcsupport  - Thank you and I was happy to help, although I do understand the outcome was unhappy for you.
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