John,
Let me think about that. The problem is that I didn’t take notes. I just muddled through and just referenced the alt-f wiki when I hit a problem. I had a few false starts and one complete restart from scratch.
Also, I’m far from an expert. As you see from the title of the post I had difficulty spotting the progress in 3.5” disks in recent years and was hoodwinked by the slim bodies into trying to fit them incorrectly to the right rather than the left of each DNS323 slot.
Anyway, back to the upgrades. Golden Rule number-1 is to deal with one drive at a time. Deliberately Fail one of the original RAID disks. Remove that drive and keep it safe. That is your fall-back if you mess up. Then you are working with one original RAID disk and one new larger disk which you want to promote. Golden Rule-2 is to make sure ONLY the new drive is ticked when you are making changes with partitions and file systems. To put it another way, double check before each step that the old RAID disk is not selected for change.
Refer to the alt-f wikis and the forum. There is a wealth of knowledge there. I had multiple pages open during my upgrade. And of course, if you are stuck, send an email. Ask the question. You will get a quick and helpful answer, or more likely, a set of answers. You are not alone, and as long as you keep at least one of your existing RAID disks safe and unchanged, you can make multiple attempts at this task. Have confidence, you WILL get there.