Was busy these few days and I needed some time to test a "live" raid migration so that I could give you a detailed step-by-step guide. The link I provided gave general pointers on how to accomplish the task and expects the reader to navigate the details.
To remove/deactivate existing RAID volumes: mdadm -S /dev/md[x], where [x] is the RAID device.
Here is the scenario on my test machine. I've got 2 drives - sda & sdb. sda is partitioned into 2 parts - sda1 (OS) & sda2 (swap).
1. Partition sdb in 1 of 2 ways*:
1a. Follow the same sizing as sda. You will get: same storage capacity, double swap space.
1b. Half the swap partition size of sda. You will get: bigger storage space, same swap space with 2 drives.
Be sure to set sdb1 partition type as fd.
2. Create your RAID volume. mdadm -C /dev/md0 --force --level=1 --raid-device=2 /dev/sdb1 missing.
3. Create you file system & swap.
mkfs -t ext3 /dev/md0
mkswap /dev/sdb2
4. Mount /dev/md0 somewhere. I mounted it on /mnt.
5. Copy (cp -R) everything from sda1 to /mnt EXCEPT /proc & /sys.
6. Create empty proc & sys folders in /mnt. mkdir /mnt/proc /mnt/sys
7. Mount the proc filesystem to /mnt/proc. mount -t proc proc /mnt/proc
8. chroot into /mnt. chroot /mnt
9. Edit /etc/fstab & /boot/grub/grub.conf (or menu.lst) and change all references of sda1 to md0. Change the reference of you swap from sda2 to sdb2 too.
10. Create the /etc/mtab file. cat /proc/mounts > /etc/mtab
11. Install the grub boot loader on sdb. Invoke the grub shell with grub. In the shell type in:
grub> root (hd1,0)
grub> setup (hd1)
grub> quit
12. Reboot your machine and unplug sda to see if your system boots up.
Now, if up to this point you system boots up fine, it's time to add sda into the mix. Remember to plug sda back into your system.
13. If sda1 and sdb1 are of different sizes (because you followed step 1b), repartition sda1 to have the same size. Else just change the partition type to fd.
14. Add sda1 into your RAID volume. mdadm /dev/md0 --add /dev/sda1. You can check the rebuild status with mdadm --detail /dev/md0.
15. Done.
* There is no point in mirroring your swap partition. Some have reported a performance penalty in doing so. Sacrificing swap space for storage is regarded by some as a big NO-NO. Besides, the additional storage gains will usually be in the 256MB to 512MB range (negligible).
--== Anything can go wrong. It's just a matter of how far wrong it will go till people think its right. ==--