NV 4x1TB -> 4x2TB nightmare! (#10777660)

Here's what I have done so far

I have a readynas NV
It has 4x1TB (xraid) 4.1.6

1) I bought 4 new 2TB drives
2) Replaced each drive one at a time
3) Rebuilt successfully after each drive replacement
4) RAID begun expansion after 4th drive was put in.
5) Never properly expanded
6) Found out I had the wrong block size so, I would need to do a factory reset (a very old device)
7) Backed up ALL data to external hard drives
8) Factory reset
9) Rebuilt okay
10) Restored old config
11) Became unresponsive
12) Factory reset again -- unresponsive -- says root corrupted
13) USB reset -- looks like it works.
14) reboot, I get two LEDs blink, then four LEDs, then two, etc...
15) check dimm -- seated okay
15) try tFTP reset -- loads up okay
16) upon reboot, it never comes back up.
17) reboot, I get two LEDs blink, then four LEDs, then two, etc...
18) USB reset -- looks like it works.
19) reboot, I get two LEDs blink, then four LEDs, then two, etc...

Please help. These are new drives, and work fine outside of the NAS with no problems. I'm at ends wit!

Thanks,
Eric