This is an update on my previous problem. On December 5, I sent my CONF.BIN to Thecus who wrote back that a newer version of the firmware that would fix the problem would be released by the end of the week. I wrote back two weeks later to ask when the firmware would be released and was told again that the firmware would be released by the end of that week. Later, a different thecus representative wrote me back with a prerelease version of the newer firmware. I installed the prerelease version of firmware v2.00.04, which did not fix the problem (the data capacity of my 500gb four disk array was still stuck at 860gb). Two days ago, I purchased a new disk and did another migration from a four disk to a five disk array, hoping this would fix the problem. It did not - my array still shows available data at 856gb, when it should be closer to 2000gb.
It has now been almost six weeks since I first sought help on this problem. I have two hard drives in my raid that cannot be used, even though the firmware says they are part of the array. The only way I see to fix this would be to copy my data from my RAID to a new one that already has all the disks, since the disk migration doesn't work, not even with the soon-to-be-released v2.00.04 firmware.
If Thecus is willing to send me a new N5200, with drives included (I'll need two 1tb drives, or three 500gb drives), I can copy the data to the new N5200 and back onto my own after reinitializing the array, then mail it back. If this is possible, reply here or email me using the email I used earlier to send you my CONF.BIN and we'll work something out. I think I've waited long enough for a solution already. This has been a huge hassle for me, so any free goodies like a credit towards future purchases or something would be nice.