Here is what I found before seeing your answer: I removed the new drive from the computer, put it into an external case and hooked it to another computer to see what the drive looked like in disk management. The RST had created the proper partitions (matching the good drive in the array) before the rebuild failed. I am wondering if these partitions are causing the failure of the rebuild? Any ideas?
I have deleted the partitions that were formed by the initial RST rebuild that failed. I have run the Seatools short generic test and the drive failed. I am now running the long generic test, which has the ability to repair difficult to read sectors.