sgi-enth.. do you by any chance have the ability to insert a drive into the machine itself (internal drive slot) and if so, with the arrays disconnected create a stone from that?
If you can and it works, then I'd do a reboot with arrays attached, start up sw_config as you do, clearAll-create the existing, set the off-sets to zero and try selecting your array drives again with add-create..
These things are pain in the butts, I recall having this issue with a SUN StorEdge and I had to do all sorts of strange things. I sometimes believe that whatever holds the stoneFS information, sometimes does not get cleared down.
Just something worth trying.
