This is the problem when you try to write up a good summary of what you found.  
I've got pages and pages of notes of all the tests I did here, far more than I 
could include in that PDF.

What makes me think it's driver is that I've done much of what you suggested.  
I've replicated the exact same behaviour on two different cards, individually 
and with both cards attached to the server.  It's also consistent across many 
different brands and types of drive, and occurs even if I have just 4 drives 
connected out of 8 on a single controller.

I did wonder whether it could be hardware related, so I tested plugging and 
unplugging drives while the computer was booting.  While doing that and 
hot-plugging drives in the BIOS, at no point did I see any hanging of the 
system, which tends to confirm my thought that it's driver related.

I was also able to power on the system with all drives connected, wait for the 
controllers to finish scanning the drives, then remove a few at the GRUB boot 
screen.  From there when I continue to boot Solaris, the correct state is 
detected every time for all drives.

Based on that, it appears that it's purely a problem with detection of the 
insertion / removal event after Solaris has loaded its drivers.  Initial 
detection is fine, it's purely hot swap detection on ports 0-5 that fails.  I 
know it sounds weird, but trust me I checked this pretty carefully, and 
experience has taught me never to assume computers won't behave in odd ways.

I do appreciate my diagnosis may be wrong as I have very limited knowledge of 
Solaris' internals, but that is my best guess right now.

Ross
 
 
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