Two related bugs:

https://bugs.launchpad.net/ubuntu/+bug/141435
https://bugzilla.novell.com/show_bug.cgi?id=328388

These turned my attention to HPA issues.
>From hdparm man page:

[...]  The difference between these two values indicates how many sectors
              of  the  disk are currently hidden from the operating system, in 
the form
              of a Host Protected Area (HPA).  This area is often used by 
computer mak‐
              ers to hold diagnostic software, and/or a copy of the originally 
provided
              operating system for recovery purposes.  To change the current 
max  (VERY
              DANGEROUS, DATA LOSS IS EXTREMELY LIKELY), a new value should be 
provided
              (in base10) immediately following the -N flag.  This value  is  
specified
              as a count of sectors, rather than the "max sector address" of 
the drive.
              Drives have the concept of a temporary (volatile) setting which  
is  lost
              on  the  next  hardware reset, as well as a more permanent 
(non-volatile)
              value which survives resets and power cycles.   By  default,  -N  
affects
              only  the  temporary  (volatile)  setting.  To change the 
permanent (non-
              volatile) value, prepend a leading p  character  immediately  
before  the
              first  digit  of  the  value.  Drives are supposed to allow only 
a single
              permanent change per session.  A  hardware  reset  (or  power  
cycle)  is
              required  before  another  permanent -N operation can succeed.

Looks like that may explain my problem if the live CD sets up a wrong
permament HPA, but then corrects the non-permanent one to the good
value, but the power off resets to the wrong value which invalidates the
array. I will try dumping my drive's setting and check whether re-
writing the correct number of sectors fixes it.


** Bug watch added: Novell/SUSE Bugzilla #328388
   https://bugzilla.novell.com/show_bug.cgi?id=328388

-- 
booting live cd breaks intel matrix raid
https://bugs.launchpad.net/bugs/383001
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