Ok last night I put each drive in turn and booted with the BIOS in RAID. It loaded everytime.
As I loaded each drive one after another, 1 and 2 loaded ok and showed up in the intel raid ctrl+I list. When I added the third drive (the one I thought was faulty at first but tested ok when I ran the WD tests) the RAID list shows disk 1, my 80gb SSD and the 2nd 500gb, the 3rd disk shows as a blank space where the S/N goes and 0.0GB as its size. I thought the drive was faulty and when I remove it and use the 1st, 2nd and 4th disks it still goes mad.
Got 4 160GB's to try when I get home.
Anyone else had anything like this? Might even try a slightly older version of the BIOS.
Kind of feel like this is a blog more than a forum now..
I've solved the problem. Rolled back the BIOS to 4405 and installed version 8.8 of the matric storage. Everything seems to be fine now. Ran some soak tests last night and everything was ok, hope its the same when I get home from work.
Which bios version were you using before you rolled it back?