Weird Drive Error

An Xserve G5 2.0GHz reported to me this morning that the drive in bay 1 had S.M.A.R.T status of "Failing". The drive is a slice in a mirrored set. As I was going through the motions of preparing how I was going to replace the drive, and while I was waiting to make a extremely relevant backup of the mirrored set before I made the plunge, the error was no longer there and Disk Utility was reporting nothing wrong. I reset the Xserve error status and everything is well. Disk Utility never once reported that the mirror was running degraded. Anyone heard of that before?
Be that as it may, in the event that this happens again, I just want to make sure I have my procedure right in swapping out the bad drive for a new drive, and rebuild the mirror.
I would power down the Xserve, replace the drive, reboot from the OS X Server DVD. Run the terminal application, add the new drive to the RAID, and rebuild the RAID. Right?

OK, here's the deal.
I removed the bad drive, no harm, no foul. Put in the new drive, tried to add the drive to the RAID and rebuild, no dice. I was using the Disk Utility app.
So I moved over to the terminal, and tried it there, no dice. It was there I discovered why I was getting a -9998 error message. The degraded RAID slice is a Hitachi 80GB, that when formatted is 76.7GB. This new drive that I literally received a few days before this problem from Apple is some other brand identified as SI.... Anyhoo it's capacity is 76.3GB and the command line feedback is that it "the target disk is too small to add to this RAID set"!
I am going to clone via SuperDuper! the degraded mirror over the 250GB partitioned drive in bay 3, and boot it up from that. For now. I am going to wait a little bit before I do this as some people are still at work.

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