Adding Raid 1 to an existing Raid 5 Environment, OS won't boot!

Our exchange server is (or actually was... R.I.P so far) running using a Raid 5 environment ...

so bascially I only had one array (array 0) with 3 hard disks in it, Raid 5, that was bootable and had the OS on it.

We realized we need more space, so we boguth 2 hard disks (2 TB each) , shut down the server, installed them offline mode , boot up, ctrl +G , created a new array, configured them as Raid 1 , restart... no boot!

I double checked, the raid 5 array is still the bootable one in the raid settings, but it just won't boot (no software error, it's as if I unpluged the hard disk or removed it from the boot options in Bios (even though I did not))

Now I am running a consistency check on both arrays, it's taking pretty long (17 hours so far), first one is at 99% seoncd is at 29% ... the entire company has no mail access..

any advices? tips? is it possible that with Raid 1 there, raid 5 is by default not bootable regardless of what options you put? (doesn't make sense but you gotta think of everything)...

the board is Intel S5000VSASATA

 

Have you checked your HCL? http://download.intel.com/support/motherboards/server/sb/hdd_test_report_rev_23_0.pdf

Also is this exchange 2003 or 2007? If so, I'd not recommend sata drives, as they can't handle the disk I/O. Now, if you use 2010, then yes, Sata should be find, since MS has decreased the required I/O overhead.

If the server does not boot, I'd disconnect the raid 1 array and hope ye can boot. Then double check that HCL.