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This is the log file.

So seeing as there is no reply telling me not to go ahead with this, I tried it out. I got got to step 6 and encoutered the same "The harddisk seems too small!" message. I recreated the array from 64KB to 128KB strip size and that message is gone.

I am trying to recover this partition labelled ...

Motherboard: Gigabyte GA-H170N-WIFI
BIOS Version: F22e
RAID System: Intel RST
Drives: (4) Intel 540s Series 2.5" 1TB SSD

Hi, I have a classic story of messing up my Intel RST capable BIOS and causing 2 RAID disks to become non-RAID, leaving me with a "Failed" RAID 5 array.

I have seen this thread ...