Hi,
your output is quite strange, you should not have this one :
Personalities : [raid1]
md1 : active raid1 sda[1] sdb1[0]
104320 blocks [2/2] [UU]
Nevertheless , let's go we'll deal with.
Whatever I will write, you should have a good backup of your data before acting !!
To join your new disk to you existing raid device, you have to recreate the identical layout, then add the partition to the raid, and voilĂ
In the folowing commands :
sdb is the live disk and
sda is your new clean disk
First, we have to get rid of your spurious disk, may be just rebooting your server might do the same job ...
[root@ixus ~]# mdadm -f /dev/md1 /dev/sda1 -r /dev/sda1
mdadm: set /dev/sda1 faulty in /dev/md1
mdadm: hot removed /dev/sda1
[root@ixus ~]#
Now the normal stuff
Dump the partition layout from one disk and apply it to the other one
[root@ixus ~]# sfdisk -d /dev/sdb > sfdisk_sdb.out
[root@ixus ~]# sfdisk /dev/sda < sfdisk_sdb.out
(this will DESTROY any data you might have on sda !)
Add the new partitions to your raid device
[root@ixus ~]# mdadm -a /dev/md1 /dev/sda1
mdadm: hot added /dev/sda1
[root@ixus ~]# mdadm -a /dev/md2 /dev/sda2
mdadm: hot added /dev/sda2
Now you can see the raid array being rebuilt
[root@ixus ~]# cat /proc/mdstat
Personalities : [raid1]
md1 : active raid1 sda1[2] sdb1[0]
104320 blocks [2/1] [U_]
[===================>.] recovery = 98.0% (102528/104320) finish=0.0min speed=9320K/sec
md2 : active raid1 sda2[2] sdb2[0]
1991936 blocks [2/1] [U_]
resync=DELAYED
unused devices: <none>
[root@ixus ~]#
I guess you understood the touchy part in all of this is getting out from your current situation : sda1 more or less part of the raid ...
Hope this helps
Gaston