Thank you Stefan for taking a look, see comments inline:

On Mon, Oct 27, 2014 at 12:32:30PM +0100, Stefan Sperling wrote:
> On Sun, Oct 26, 2014 at 09:19:25PM +0100, Patrik Lundin wrote:
> > 
> > # disklabel -E wd0
> > Create the following partitions (in this order to make the biggest
> > partition last):
> > wd0b (swap) 
> > wd0d (RAID) - keydisk (1M)
> > wd0a (RAID) - the remaining part of the drive that will be encrypted.
> 
> I'd use wd0d instead of wd0a, because 'a' is usually expected
> to contain a root partition, not a softraid volume. That has
> nothing to do with the problem at hand though.
> 

Given that wd0d is used for the keydisk, do you mean i
should use wd0e for the remainder of the drive instead of 'a'?

Would this also mean I should skip creating a sd0a altogether?

> > ===
> > Using drive 0, partition 3.
> > Loading.....
> > ERR M
> > ===
> 
> This error means biosboot(8) can't find the boot(8) program.
> When booting from softraid, the boot program is stored at a particular
> offset in the softraid meta data area, and installboot(8) patches that
> offset into biosboot(8) before copying biosboot(8) to the MBR.
> Apparently, biosboot(8) has the wrong offset in your case.
> 

Hmm, interesting, thanks for the description!

> Your report lacks some information:
> - architecture (i386 / amd64 / ...)

I am using amd64.

> - full output of 'disklabel wd0' to show exactly how you configured
>   partitions

I stuck to my original layout for consistency (this has been written
down by hand):

===
# disklabel wd0
# /dev/rwd0c:
type: ESDI
disk: ESDI/IDE disk
label: VBOX HARDDISK
duid: 175d4587e45a04a5
flags:
bytes/sector: 512
sectors/track: 63
tracks/cylinder: 255
sectors/cylinder: 16065
cylinders: 3916
total sectors: 62914560
boundstart: 64
boundend: 62910540
drivedata: 0

16 partitions:
#           size     offset  fstype [fsize bsize cpg]
  a:    58685445    4225095    RAID
  b:     4208966         64    swap
  c:    62914560          0  unused
  d:       16065    4209030    RAID
===

So wd0a is 28GB, wd0b is 2G, and wd0d is 7.8M.

> - output of running installboot with the -v option on the softraid
>   volume: installboot -v sd0
> 

Since I am not able to boot on the device i have to run installboot as
the last step in the installer. For this i need to add -r /mnt (of
course the following is also copied by hand):

===
# installbook -v -r /mnt sd0
Using /mnt as root
installing bootstrap on /dev/rsd0c
using first-stage /mnt/usr/mdec/biosboot, second-stage /mnt/usr/mdec/boot
sd0: softraid volume with 2 disk(s)
sd0: installing boot loader on softraid volume
/mnt/usr/mdec/boot is 5 blocks x 16384 bytes
wd0a: installing boot blocks on /dev/rwd0c, part offset 4225175
master boot record (MBR) at sector 0
       partition 3: type 0xA6 offset 64 size 62910476
/mnt/usr/mdec/biosboot will be written at sector 64
wd0d: installing boot blocks on /dev/rwd0c, part offset 4209110
master boot record (MBR) at sector 0
        partition 3: type 0xA6 offset 64 size 62910476
/mnt/usr/mdec/biosboot will be written at sector 64
===

> > 
> > When I do this the system manages to boot without a passphrase, using
> > the encrypted drive.
> 
> I suspect there is a problem in installboot(8) in case the keydisk is
> on the same disk as the crypto volume. The boot(8) program which is the
> first program to interpret softraid meta data doesn't even get to run
> in your case.
> 

I see, I hope the output I supplied above can give you some insight!

Regards,
Patrik Lundin

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