Here is the scenario you or a client have a remote machine that was installed as a standard/default minimal Centos 6.x machine on a single disk with LVM for whatever reason. Often many people do not know how to install it to a RAID array so it is common to have this problem and why reinstall if you don't need to? In some cases on a remote system you can't easily reinstall without physical or KVM access.
So in this case you add a second physical or disk or already ha........
Before we start I take no responsibility for this, you should have a backup and if you make a mistake during this process you could wipe out all of your data. So backup somewhere else before starting this as a precaution, or make sure it's data you could afford to lose.
The RAID 1 Setup (Hardware Wise)
I've already setup my 2 x 1TB (Seagate) drives with identical partitions, make sure your new hard drive (the empty one) is setup like your curr........
I have no idea why but mkfs.ext3 defaults to a patheticlly small blocksize of 1024 bytes/1KB (kilobyte). That means the maximum filesize is ONLY 16GB! With 2KB/2048 bytes you get a 256 GB maximum filesize, and with 4KB/4096 bytes you get 2TB!
I finally noticed/paid attention to this after realizing that with rsync and scp that no file larger than 17GB could be transferred. I then realized it must be a file size limit on the partition.
Here is what tune2fs tol........