I have a zfs pool made of two vdevs, each using one whole physical disk, under 
OpenSolaris 2008.5.
Disks live on a Netcell SATA/RAID controller, that has three ports (and I 
planned to use three disks there, and configure mirrors in zfs), but as it 
turned out could only provide one or two disks to the system. So I decided to 
create a mirror of two identical drives  on controller instead of one of the 
vdevs in zfs pool.

I did a 'dd' dump of whole disk of second vdev, and created an array on 
controller with second disk to mirror that one. After booting to Solaris 'zpool 
status' reported that it can't use the disk because label is missing or 
corrupted. I restored the dump made previously with dd - and 'zpool status' 
reported vdev in state FAILED, data corrupted, ~100k files with errors. Upon 
reboot, controller's BIOS reported that one of the disks in mirror is failing 
and needs to be replaced.

So I rebuilt an array. After booting, ZFS still reports disk as FAILED. An 
attempt to scrub crushes and reboots the system. Restoring the dump makes array 
broken from controller's point of view. It seems it stores some configuration 
information on disk, and that conflicts with ZFS using whole disk. This is an 
example of when using whole disk for ZFS is not a good idea. I reverted to 
using one-disk array on controller, as it was when I created zfs filesystem, 
but that does not help either. 'zdb -l' "fails to unpack" label 0 and 1. 2 and 
3 look ok to me, showing correct zfs info. 'format' reports this disk as being 
the part of active zfs pool (as well as for the other disk, that was part of a 
mirror and now connected via USB). 'zfs replace' also does not want to replace 
because it thinks second disk is part of active pool.

Is there a way to recover from this problem? I'm pretty sure the data is still 
OK, it's just labels that get "corrupted" by controller or zfs. :(
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