raid5 with 2 disks not working correctly. Need help!

["Roy Lim" <cableroy@gmail.com>]

Hi
I have ran into a serious problem with my raid5 array and need expert
help on this one.

My array is with 5x500GB disks none spare, I've accidentally did a
unclean shutdown of the server. When it came up it gave me this error:

Dec 15 09:07:11 ares kernel: md: kicking non-fresh hdk1 from array!
Dec 15 09:07:11 ares kernel: md: unbind<hdk1>
Dec 15 09:07:11 ares kernel: md: export_rdev(hdk1)
Dec 15 09:07:11 ares kernel: md: md0: raid array is not clean --
starting background reconstruction
Dec 15 09:07:11 ares kernel: raid5: device hde1 operational as raid disk 0
Dec 15 09:07:11 ares kernel: raid5: device sda1 operational as raid disk 4
Dec 15 09:07:11 ares kernel: raid5: device hdi1 operational as raid disk 2
Dec 15 09:07:11 ares kernel: raid5: device hdg1 operational as raid disk 1
Dec 15 09:07:11 ares kernel: raid5: cannot start dirty degraded array for md0

However i managed to get this back up with remove and add, the system
was rebuilding the array. around 70-80% in the process i was going to
prepare to decrypt it (luks crypted) so I'm going to mount the usb
stick witch has the encryption key however when i was going to mount
it i tried to mount wrong device, resulting trying to mount a device
in the array (sda1) i hit repeatedly crtl+c, now taking a look at the
details on the array it looks like this:

/dev/md0:
        Version : 00.90.03
  Creation Time : Mon Feb  4 18:25:28 2008
     Raid Level : raid5
     Array Size : 1953535744 (1863.04 GiB 2000.42 GB)
    Device Size : 488383936 (465.76 GiB 500.11 GB)
   Raid Devices : 5
  Total Devices : 5
Preferred Minor : 0
    Persistence : Superblock is persistent

    Update Time : Mon Dec 15 16:02:54 2008
          State : clean, degraded
 Active Devices : 3
Working Devices : 4
 Failed Devices : 1
  Spare Devices : 1

         Layout : left-symmetric
     Chunk Size : 64K

           UUID : 856a6e4e:a1663e98:9efbd2b1:7507133b
         Events : 0.74

    Number   Major   Minor   RaidDevice State
       0      33        1        0      active sync   /dev/hde1
       1      34        1        1      active sync   /dev/hdg1
       2      56        1        2      active sync   /dev/hdi1
       3       0        0        3      removed
       4       0        0        4      removed

       5      57        1        -      spare   /dev/hdk1
       6       8        1        -      faulty spare   /dev/sda1

a quick summary: hdk1 was the one failing in the first place, witch
was about to get rebuild, sda1 was the device i tried to mount while
reconstruction the data. As you can see, hdk1 is now marked as spare
and sda1 a faulty spare.  I have not touch the array after this. Can
anyone help me out? How can i force mdadm to set the sda1 to active
sync so i can mount the array and start a backup? Can i use dd_rescue
to file of all of the disks and play with it?

All help is appreciated!

/Roy