On Tue, 12 Mar 2013, Javier Marcet wrote:

I have filed the RMAs and ordered a new disk so that I can at least copy 
some of the data. Yet I have been thinking I could clone the drive which 
is still part of the array and has one bad sector over the new one and 
try to assemble the raid with the clone.

Could that work?

Yes, to use dd_rescue or gddrescue for this purpose is very common.

-- 
Mikael Abrahamsson    email: swmike@swm.pp.se