tomas@ubuntu:~$ sudo su
[sudo] password for tomas:

#clear boot partition
root@ubuntu:/home/tomas# dd if=/dev/zero of=/dev/sdb bs=512 count=64260
64260+0 records in
64260+0 records out
32901120 bytes (33 MB) copied, 1.56911 s, 21.0 MB/s

# check
root@ubuntu:/home/tomas# /sbin/sfdisk -l /dev/sdb
Disk /dev/sdb: 60801 cylinders, 255 heads, 63 sectors/track
sfdisk: ERROR: sector 0 does not have an msdos signature
 /dev/sdb: unrecognized partition table type
No partitions found

# fdisk reads lines of the form     <start> <size> <id> <bootable>
# When a field is absent or empty, a default value is used.
# The default value of size is as much as possible (until next partition or end-of-disk).
root@ubuntu:/home/tomas/1# echo 4,244,fd>DSKPART
root@ubuntu:/home/tomas/1# echo 248,32,fd>>DSKPART
root@ubuntu:/home/tomas/1# echo 280,123,fd>>DSKPART
root@ubuntu:/home/tomas/1# echo 403,,fd>>DSKPART
root@ubuntu:/home/tomas/1# /sbin/sfdisk --force /dev/sdb <./DSKPART
Disk /dev/sdb: 60801 cylinders, 255 heads, 63 sectors/track
sfdisk: ERROR: sector 0 does not have an msdos signature
 /dev/sdb: unrecognized partition table type
Old situation:
No partitions found
New situation:
Units = cylinders of 8225280 bytes, blocks of 1024 bytes, counting from 0

   Device Boot Start     End   #cyls    #blocks   Id  System
/dev/sdb1          4     247     244    1959930   fd  Linux raid autodetect
/dev/sdb2        248     279      32     257040   fd  Linux raid autodetect
/dev/sdb3        280     402     123     987997+  fd  Linux raid autodetect
/dev/sdb4        403   60800   60398  485146935   fd  Linux raid autodetect
Warning: no primary partition is marked bootable (active)
This does not matter for LILO, but the DOS MBR will not boot this disk.
Successfully wrote the new partition table
Re-reading the partition table ...

# if you have a disc with partitions
# now look for automounted raid devices and stop this raid arrays
# in ubuntu i have md_d1 / md_d0 / md_d3
root@ubuntu:/home/tomas/1# cat /proc/mdstat
Personalities : [linear] [multipath] [raid0] [raid1] [raid6] [raid5] [raid4] [raid10]
md_d1 : active raid1 sdb2[0]
      256960 blocks [2/1] [U_]
md_d0 : active raid1 sdb1[0]
      1959808 blocks [2/1] [U_]
md_d3 : active raid1 sdb3[0]
      987904 blocks [2/1] [U_]

# and stop this raid arrays!!
root@ubuntu:/home/tomas/1# mdadm --stop /dev/md_d0
root@ubuntu:/home/tomas/1# mdadm --stop /dev/md_d1
root@ubuntu:/home/tomas/1# mdadm --stop /dev/md_d3
root@ubuntu:/home/tomas/1# mdadm --zero-superblock /dev/sdb1
root@ubuntu:/home/tomas/1# mdadm --zero-superblock /dev/sdb2
root@ubuntu:/home/tomas/1# mdadm --zero-superblock /dev/sdb3
root@ubuntu:/home/tomas/1# mdadm --zero-superblock /dev/sdb4


# make three raid partitions (md0 md1 md3)
# type y for "yes" !
root@ubuntu:/home/tomas/1# mdadm --create /dev/md0 -l 1 -n 2  /dev/sdb1 missing
mdadm: /dev/sdb1 appears to contain an ext2fs file system
    size=1959808K  mtime=Thu Jan  1 01:00:02 1970
mdadm: /dev/sdb1 appears to be part of a raid array:
    level=raid1 devices=2 ctime=Tue Feb 12 23:58:30 2008
Continue creating array? y
mdadm: array /dev/md0 started.
root@ubuntu:/home/tomas/1# mdadm --create /dev/md1 -l 1 -n 2  /dev/sdb2 missing
mdadm: /dev/sdb2 appears to be part of a raid array:
    level=raid1 devices=2 ctime=Tue Dec  8 00:07:57 2009
Continue creating array? y
mdadm: array /dev/md1 started.
root@ubuntu:/home/tomas/1# mdadm --create /dev/md3 -l 1 -n 2  /dev/sdb3 missing
mdadm: /dev/sdb3 appears to contain an ext2fs file system
    size=987904K  mtime=Thu Jan  1 01:00:03 1970
mdadm: /dev/sdb3 appears to be part of a raid array:
    level=raid1 devices=2 ctime=Tue Dec  8 00:08:06 2009
Continue creating array? y
mdadm: array /dev/md3 started.

#clear 4. partition
root@ubuntu:/home/tomas/1# dd if=/dev/zero of=/dev/sdb4 bs=512 count=1
1+0 records in
1+0 records out
512 bytes (512 B) copied, 0.00614513 s, 83.3 kB/s

# format the raid partitions
root@ubuntu:/home/tomas/1# mkfs.ext3 /dev/md0
mke2fs 1.41.9 (22-Aug-2009)
Filesystem label=
OS type: Linux
Block size=4096 (log=2)
Fragment size=4096 (log=2)
122640 inodes, 489952 blocks
24497 blocks (5.00%) reserved for the super user
First data block=0
Maximum filesystem blocks=503316480
15 block groups
32768 blocks per group, 32768 fragments per group
8176 inodes per group
Superblock backups stored on blocks:
    32768, 98304, 163840, 229376, 294912

Writing inode tables: done
Creating journal (8192 blocks): done
Writing superblocks and filesystem accounting information: done

This filesystem will be automatically checked every 32 mounts or
180 days, whichever comes first.  Use tune2fs -c or -i to override.

root@ubuntu:/home/tomas/1# mkswap /dev/md1
mkswap: /dev/md1: warning: don't erase bootbits sectors
        on whole disk. Use -f to force.
Setting up swapspace version 1, size = 256956 KiB
no label, UUID=5afd945c-90ec-4cbf-8ce2-06d25b5f8a30

root@ubuntu:/home/tomas/1# mkfs.ext3 /dev/md3
mke2fs 1.41.9 (22-Aug-2009)
Filesystem label=
OS type: Linux
Block size=4096 (log=2)
Fragment size=4096 (log=2)
61824 inodes, 246976 blocks
12348 blocks (5.00%) reserved for the super user
First data block=0
Maximum filesystem blocks=255852544
8 block groups
32768 blocks per group, 32768 fragments per group
7728 inodes per group
Superblock backups stored on blocks:
    32768, 98304, 163840, 229376

Writing inode tables: done
Creating journal (4096 blocks): done
Writing superblocks and filesystem accounting information: done

This filesystem will be automatically checked every 31 mounts or
180 days, whichever comes first.  Use tune2fs -c or -i to override.

# download the latest firmware - also see /proto/SxM_webui/admin/fw_chk.php
root@ubuntu:/home/tomas/1# wget http://cache.websupport.wdc.com/wdhxnc-01.00.16.img -O ./fw.img
--2009-12-12 16:51:41--  http://cache.websupport.wdc.com/wdhxnc-01.00.16.img
Resolving cache.websupport.wdc.com... 81.22.36.106
Connecting to cache.websupport.wdc.com|81.22.36.106|:80... connected.
HTTP request sent, awaiting response... 200 OK
Length: 48864982 (47M) [text/plain]
Saving to: `./fw.img'
100%[===========================================================>] 48,864,982   145K/s   in 5m 46s
2009-12-12 16:57:35 (138 KB/s) - `./fw.img' saved [48864982/48864982]

# "decode" the firmware image and clean up
dd skip=0 count=1 bs=5120 if=./fw.img of=./tmp_img1
dd skip=15 count=1 bs=5120 if=./fw.img of=./tmp_img2
cp ./fw.img ./fw_img.orig
dd seek=0 count=1 bs=5120 if=./tmp_img2 of=./fw.img
dd skip=1 seek=1 bs=5120 if=./fw_img.orig of=./fw.img
cp ./fw.img ./fw_img.orig
dd seek=15 count=1 bs=5120 if=./tmp_img1 of=./fw.img
dd skip=16 seek=16 bs=5120 if=./fw_img.orig of=./fw.img
rm ./tmp_img1
rm ./tmp_img2
rm ./fw_img.orig

# extract gzipped image .tar.gz
root@ubuntu:/home/tomas/1# tar zxf ./fw.img

# check if md5sum matches
root@ubuntu:/home/tomas/1# md5sum -c upgrd-pkg-1nc.wdg.md5
upgrd-pkg-1nc.wdg: OK

# unpack firmware to /fw
root@ubuntu:/home/tomas/1# mkdir ./fw
root@ubuntu:/home/tomas/1# SKIP=`awk '/^__ARCHIVE_FOLLOWS__/ {print NR +1; exit 0 }' ./upgrd-pkg-1nc.wdg`
root@ubuntu:/home/tomas/1# echo $SKIP
18
root@ubuntu:/home/tomas/1# tail -n+${SKIP} ./upgrd-pkg-1nc.wdg | gunzip  | /bin/tar xm -C ./fw

# check md5sums
root@ubuntu:/home/tomas/1# cd ./fw
root@ubuntu:/home/tomas/1/fw# md5sum -c md5sum.lst
packing.lst: OK
reserve.list: OK
reserve.sh: OK
rootfs.arm.ext2: OK
u-boot.wrapped: OK
uImage: OK
uImage.1: OK
upgrade1.sh: OK
upgrade1-xdelta.sh: OK
upgrade2.sh: OK
uUpgradeRootfs: OK
root@ubuntu:/home/tomas/1/fw# cd ..

# mount
root@ubuntu:/home/tomas/1# mkdir ./sdb1
root@ubuntu:/home/tomas/1# mkdir ./sdb3
root@ubuntu:/home/tomas/1# mkdir ./rootfs
root@ubuntu:/home/tomas/1# mount -o rw,noatime /dev/md0 ./sdb1
root@ubuntu:/home/tomas/1# mount -o rw,noatime /dev/md3 ./sdb3
root@ubuntu:/home/tomas/1# mount -o loop,ro,noatime ./fw/rootfs.arm.ext2 ./rootfs


# rootfs: copy files to /sdb1
root@ubuntu:/home/tomas/1# cp -a ./rootfs/* ./sdb1

# /var: copy files to /sdb3
root@ubuntu:/home/tomas/1# cp -a ./rootfs/var/* ./sdb3


# set the factory_restore flag -> that rebuild a clean md2=sda4 after reboot
root@ubuntu:/home/tomas/1# echo final_tested_ok > ./sdb1/etc/mfgtest_state
root@ubuntu:/home/tomas/1# touch ./sdb1/etc/.factory_restore

# !!!! if you have a non WDC Disc !!!!!
# use an editor and comment out following lines 166 and 169 in
# proto/SxM_webui/admin/tools/factoryDefault.sh
mdadm --assemble /dev/md0 /dev/sdb1

root@ubuntu:/home/tomas/1# cat -n ./sdb1/proto/SxM_webui/admin/tools/factoryDefault.sh | head -170l | tail -8l
   163  if [ "$MODEL" != "WWLXN" ]; then
   164    let DISK_COUNT=DISK_COUNT+1
   165    cat /sys/block/sdb/device/model | grep WDC >/dev/null 2>&1
   166  #  if [ "$?" -eq "0" ]; then
   167        let WD_DISK_COUNT=WD_DISK_COUNT+1
   168        DISK2=sdb
   169  #  fi
   170  fi
# the file system is ready -> stop Raid
root@ubuntu:/home/tomas/1# umount ./sdb1
root@ubuntu:/home/tomas/1# umount ./sdb3
root@ubuntu:/home/tomas/1# umount ./rootfs
root@ubuntu:/home/tomas/1# mdadm --stop /dev/md0
mdadm: stopped /dev/md0
root@ubuntu:/home/tomas/1# mdadm --stop /dev/md1
mdadm: stopped /dev/md1
root@ubuntu:/home/tomas/1# mdadm --stop /dev/md3
mdadm: stopped /dev/md3
root@ubuntu:/home/tomas/1# sync