> If my new replacement SSD with identical part number and firmware is 0.001
> Gb smaller than the original and hence unable to mirror, what's to prevent
> the same thing from happening to one of my 1TB spindle disk mirrors?

There is a standard for sizes that many manufatures use (IDEMA LBA1-02):

LBA count = (97696368) + (1953504 * (Desired Capacity in Gbytes – 50.0)) 

Sizes should match exactly if the manufacturer follows the standard.

See:
http://opensolaris.org/jive/message.jspa?messageID=393336#393336
http://www.idema.org/_smartsite/modules/local/data_file/show_file.php?cmd=download&data_file_id=1066
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