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Hi Gary,
Thanks for going to all that effort. In the end I stuck with mdadm and now have it working. OpenSuSE also recognises the array, so all good there too.
I mucked around for a while trying to be fancy. Late last night I read how you can create an array from a disk containing data by adding it to an array (of 2) while listing the second drive as 'missing', then add the second disk and then resync. So I copied (slooowly) from the NAS overnight and tried it. Nah. Wasted about 45min getting it wrong before I finally conceded and started from scratch. Data is copying as I type.
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