It's been a while since I've really worked with direct attached storage but I don't think there's a way to "extend" a logical drive once it's been defined. The problem is that the container is defined at a lower level than the OS. The RAID controller presents a disk to the OS. The OS isn't aware that the drive is a logical drive and not a physical one so things like partition extenders won't work. You could do step 1 and once the container fully rebuilds after the last drive swap you could then go into the controller and create a 2nd logical drive on the remaining space on each drive. Then you could setup a span volume in you OS, but that's the silly way around the problem.

There is an app called Acronis True Image (www.acronis.com) that works like Ghost (on steroids). Ghost should also work (I've had some luck if using the correct switches - you'll need to look up the launch parameters ghost.exe /x /x /x /x that relate to SCSI controllers). Basically you need to image the server as is, replace the drives, nuke the container (logical drive) in the controller's NVRAM, define a new logical drive (with whatever RAID level you want) and restore to the new logical drive. If you had a SAN and extended the container you could use diskpart or some other partition utility but I don't think there's a way to do that with direct attached storage.

Tony