Wes Morgan wrote:
You might try creating the pool, saving the first 512k of each block device to a file, then export the pool and repeat, then import (or try to). Run zdb on each file and compare the output. From creation to export to import they should only differ by the "state" in the top level of the label nvlist. If the entire label is corrupted, then likely it's a crypto problem.

Although, it really sounds like you've been able to eliminate zfs as a culprit.
This is pretty much what I tried. between export, geli detach, and geli attach, zdb -l went from reporting info on the pool to reporting that no labels were found. dd confirmed what zdb was saying, so I have no reason to think zfs is acting up. I just don't get why I haven't been able to reproduce this with another zpool-less disk or two md disks. Maybe the .eli device shows up before it's ready to use and something gets cached by zfs in the background. Maybe it has something to do with me using two disks. A race condition? None of these are really easy things to find.

For now, the only two ideas I have are trying zfs on a single disk with this configuration, and trying it on multiple disks, when the RMA is done, with 2 disks.
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