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PCI RAID card upgrading drives

We're using a PCI RAID card in an XServe with 3 400 GB drives in a RAID 5 configuration. The drives are getting somewhat full, so we're looking into how to expand the space in that machine. This machine is in a hosted facility without further space available to it, so the easiest thing to do is to keep things down to the single 1 U space.

One solution is to build a new machine using 600 GB drives and swap it out.

My question is whether people have experience sequentially swapping drives on the PCI RAID card sequentially? With other RAID setups I've been able to swap a drive, allow a rebuild, swap the next drive etc... until all drives are upgraded. Then I have some unused space on each drive which I can use to create an additional volume.

Has anyone done this on the PCI RAID card? If so, were you able to successfully do it non-destructively, preserving the data on the existing volume? I realize there will a period of non-redundancy and the end state will have a separate volume rather than an expanded one, but this would be easier than building a new server.

Thanks,
Ware Adams
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