G4 Dual 1.33 GHz Xserve: Replacing one of the mirrored drives

One of the drives in a (Disk Utility) mirrored array from the boot volume is damaged and not repairable. It was one of the original drives shipped with the Xserve, a Hitachi Deskstar 180GB ATA/IDE drives. This drive is now hard to find new, so I was wondering if I could easily just replace it with another ATA/IDE HD of a larger size, rebuild the array and then swap in another of the same new HD for the old good one.
Are there any problems with this scenario?
Chris

This should maintain my original 180GB mirrored array and give me two new 70GB partitions to mirror or possibly do something else with. Is this correct?
No can do.
You can only mirror disks, not partitions. Whatever partition map it has will be replaced if you add this drive to the mirror.
Later versions support mirroring at the partition level - IIRC I'm not sure if that's a 10.5 thing or an Intel/GUID partition map thing, but I know it isn't supported on the G4's running Tiger.
Do I HAVE to partition the new drive at a 180GB to match the old one or can I just add the 250GB partitioned drive?
You can just add the 250. The OS will treat it just like a 180GB drive to match the existing RAID members and the additional space will be lost.
Would I be better off creating a disk image of the array, add the two new 250GB disks, create the array and then restore the image to the new array
If you want the larger space then, sure, get a pair of 250's. Build a mirror using them and copy the data over.
Would Carbon Copy Cloner be good for this?
It would do it, but you can also clone the drive through either Disk Utility or the command-line asr.

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