I've been beating my head against this for the second day now, and think I'm going in circles now, so could use some external guidance please.
This is in a laptop with two hard drives running opensuse 11.1.
I setup raid1 (mirror) between the two drives.
md0 mounts root / using sda8 and sdb8
md1 mounts /home user sda9 and sdb9

/home is also encrypted (LUKS password at boot time).
And I (think) I added a second layer of encryption (but not sure at this point) encrypted the specific director /home/user.

This system has been purring along fine with this setup for months. All of a sudden on a boot up yesterday afternoon (it was working earlier on bootup that morning), I couldn't access /home anymore. It didn't ask for the LUKS password, and showed errors on the bootup indicating that the md1 was not a device, and so crypt couldn't load.
md0 loads fine (root).

When the system boots or runs /etc/init.d/boot.crypt-early it fails because md1 fails (or the interdependency between them).

Here is some output, maybe folks can help point me in the right direction, I've tried dozens of sites and forums approaches from previous others postings, but not quite getting there.

Here some info:

v9:/ # cat /etc/mdadm.conf
DEVICE partitions
ARRAY /dev/md0 level=raid1 UUID=cc67b93f:c23c38d7:6a446079:1726b629
ARRAY /dev/md1 level=raid1 UUID=adb90daa:7e594eba:f6dc04c6:73a5d54a


cat /etc/crypttab
cr_md1 /dev/md1 none none

mdadm -E /dev/sda9
/dev/sda9:
Magic : a92b4efc
Version : 1.0
Feature Map : 0x1
Array UUID : adb90daa:7e594eba:f6dc04c6:73a5d54a
Name : 1
Creation Time : Fri Dec 5 20:22:43 2008
Raid Level : raid1
Raid Devices : 2

Avail Dev Size : 104920304 (50.03 GiB 53.72 GB)
Array Size : 104920304 (50.03 GiB 53.72 GB)
Super Offset : 104920432 sectors
State : active
Device UUID : 7d0b8cee:55afb0b5:2f6d4ca3:c820e941

Internal Bitmap : -101 sectors from superblock
Update Time : Tue Apr 7 10:30:12 2009
Checksum : 4dad99ba - correct
Events : 0


Array Slot : 2 (0, 1)
Array State : uu



mdadm -E /dev/sdb9
/dev/sdb9:
Magic : a92b4efc
Version : 1.0
Feature Map : 0x1
Array UUID : adb90daa:7e594eba:f6dc04c6:73a5d54a
Name : 1
Creation Time : Fri Dec 5 20:22:43 2008
Raid Level : raid1
Raid Devices : 2

Avail Dev Size : 104920304 (50.03 GiB 53.72 GB)
Array Size : 104920304 (50.03 GiB 53.72 GB)
Super Offset : 104920432 sectors
State : active
Device UUID : 776ec64a:5a5f3aef:37170c0e:0969cccb

Internal Bitmap : -101 sectors from superblock
Update Time : Tue Apr 7 10:30:12 2009
Checksum : d8149f11 - correct
Events : 17


Array Slot : 1 (0, 1)
Array State : uU



cat /proc/mdstat
Personalities : [raid1] [raid0] [raid6] [raid5] [raid4]
md0 : active raid1 sdb8[0] sda8[1]
31463196 blocks super 1.0 [2/2] [UU]
bitmap: 3/241 pages [12KB], 64KB chunk

unused devices: <none>

dv9:/ # /etc/init.d/boot.crypto-early start
Activating crypto devices using /etc/crypttab ...
Command failed: Not a block device
/dev/md1... failed

dv9:/ # /etc/init.d/boot.md start
Starting MD Raid mdadm: failed to RUN_ARRAY /dev/md/1: Input/output error
failed

dv9:/ # mdadm -S /dev/md1
mdadm: stopped /dev/md1
dv9:/ # mdadm -A /dev/md1
mdadm: failed to RUN_ARRAY /dev/md/1: Input/output error


/var/log/messages:
Apr 8 12:13:53 dv9 kernel: md: md1 stopped.
Apr 8 12:13:53 dv9 kernel: md: bind<sda9>
Apr 8 12:13:53 dv9 kernel: md: bind<sdb9>
Apr 8 12:13:53 dv9 kernel: md: kicking non-fresh sda9 from array!
Apr 8 12:13:53 dv9 kernel: md: unbind<sda9>
Apr 8 12:13:53 dv9 kernel: md: export_rdev(sda9)
Apr 8 12:13:53 dv9 kernel: md: md1: raid array is not clean -- starting background reconstruction
Apr 8 12:13:53 dv9 kernel: raid1: raid set md1 active with 1 out of 2 mirrors
Apr 8 12:13:53 dv9 kernel: md1: bitmap file is out of date, doing full recovery
Apr 8 12:13:53 dv9 kernel: md1: bitmap initialisation failed: -5
Apr 8 12:13:53 dv9 kernel: md1: failed to create bitmap (-5)



Thanks for any suggestions.





What else can I provide? Does anything jump out at anyone as to what's wrong?

I've run the BIOS's HD test and checked smart and no errors on either drive there.