Issue with hard drive upgrade and xraid

Hmm, that only accounts for 6 of the 8 drives, so something more is wrong.  Are you sure it's 8 drives and was 8 before swapping any?  If it were 8, it should already have been RAID6 under XRAID.

I think I can understand why the last drive (which from the information given should be the 8th, not the 6th) didn't get the last partition and didn't get added to the RAID.  At that point, the unit was in FlexRAID.  And FlexRAID expects to operate on all drives at the same time, not incrementally as with XRAID.  So, it didn't know what to do with that lone drive.  But all but that last one should have been added to the volume as the drives were replaced in XRAID.  The information StephenB posted seems to indicate that they were.  But maybe the OS is confused since that last expansion didn't take place.

As StephenB said, the volume is expanded, it just didn't (fully) expand this time.  So the message that you can't go from FlexRAID to XRAID with an expanded volume is appropriate (to the extent that's a limitation of the OS).