General Protection Fault and trouble striping a new disk to replace a problematic one.

In need of help from data professionals. 

I have an old unit, it has served me well for years.  The last few I have had problems where the nas would freeze and i would have to hard reboot.  I kept an eye on the smart status of the disks and noticed some had ata problems and other issues as they were just regular desktop drives.  I started replacing them with RED NAS disks thinking it would solve the problem. To no avail. (althought, the temps, errors, etc have stopped on those drives).

I recently decided I would replace the overheating and error throwing disks with new 3TB RED NAS disks.  So Monday, I started with disk 1.  I did a hot swap and it would start the striping process,  only to freeze after an hour or too.  The frontview would also become unresponsive.   I read a thousand blogs and it seemed my only course of action was to shut it down and let it start striping again. It would get further then freeze. rinse, repeat.  I thought it was a serious problem so i put the old disk in. It decided it would restripe with that disk but at an extreme slow rate.   maybe 3 hours to get to 1.2%. I decided I made a mistake.  I shut it down and put the new drive back in.  Striping continued.  It would make some progress and then  freeze.  reboot.  I realized that i could quickly get the full logs out after a hard reboot. That is when I saw the General Protection Fault.  I continued this process of hard stopping and turning it back on.  It would make progress, but in small increments.  All the while I would take a log extract along the way.  

Finally today it reached 100% striping.  Then I received the error that the nas was unprotected.  I was hoping it would be fixed. After another freeze and hard reboot, it is striping again from 0% (however it doesn't say drive 1 is dead).  I am at 1.4% striped and it is frozen.  I have no idea what to do.

I have about 8 TB of movies and data so a backup is inconceivable.  I have to stick with this drive 1 and fixing it.

I have several full log files available and will try to attach to this conversation.  I have to get this working or I will lose years of data.

I hope someone out there can help. I have seen other General Fault Protection conversations, but none with a fix.

I have purchased more drives to replace the ones with errors. and I will replace them as soon as I can get this first one working.

Also, my frontview works occasionally when I first boot the NAS. I suspect more problems are in place.

Some more details:
Using Raidar 6.1 for Mac

Bios: 10/03/2008 FLAME6-MB V1.6

Firmware: 

RAIDiator-x86 Version 4.2.30 (for 1500/2100/3100/3200/4200/NVX/Pro/Pro Pioneer/Ultra/Ultra Plus)

Please let me know if additional info is needed. i have included everything i can think of

Thanks in advance,

Casey