I decided to take a different approach. But I must say that one big frustration is that no matter what I did I could not make TFTP to work – tried for days and many different approaches and no luck. So, even though I upgraded if I ever need to start from scratch – then I will be out of luck completely.
Also I need to say that initially (because I read so many negative things about the 4K byte-sector drives) that I returned my WD20EARS and replaced for WD2002FAEX – although I still could not make TFPT work. So it may not have been because of the drives -- but too late.
So, the approach I took eventually was the following.
1) I format both drives to FAT32 initially
2) I placed a new drive and one old drive in the Buffalo NAS
3) The NAS OS created and repaired the RAID partitions on the new drive – took several hours
4) Then I swapped the new drive to the 2nd one to do same with 2nd one
5) Once both new drives had the RAID partition created – I placed both new drives in the NAS
6) With both new drives in the NAS I changed the RAID to NO-RAID
7) Then I recreated RAID-1 -- by doing step 6 and 7 I re-created the RAID partitions and now it recognizes the full 2 Tb of the drives. The checking process lasted about 8 hours.
8) Transferred data from my back-up and done
Must say that on my first attempt I tried (after step 3) to increase the partition using Parted Magic but did not allowed me to do this. So I followed the above and worked. But again, if any day I need to start from scratch I will be out-of-luck since I could not do the TFPT.
One last thing. Not only I was very happy having the extra capacity – but I was extremely surprised with the new SPEED! While testing the new drives after loading them with data from my backup I was completely surprised! I was not expecting the performance to be so dramatically different! WOW!!!!!!!!!!!!!!!!!
How can disks make such a difference? Mainly I always thought that the main response lag was because I was accessing over the network – but they feel like 3 times faster. Even when using my laptop over WiFi! Could it be the buffer size and can the buffer make such a difference?
New Disk Drives are Western Digital Caviar Black model WD2002FAEX
These drives have 6 Gb/s transfer rate (not sure if the Buffalo NAS takes advantage of this) but also has 64 Mb of Buffer and also dual processor. http://www.wdc.com/en/products/products.aspx?id=100
The prior drives were Samsung HE103UJ
Specs are 3 Gb/s transfer, 32 Mb of Buffer and dual-ARM based firmware
So -- would the buffer alone make that dramatic difference?
Ok – One last-last thing. I also noticed that the new drives run much, MUCH!, hotter. The new WD2002FAEX runs very hot! So, I hope the heat now does not render them short lived.