And so like a Lemming, I went back again and tried re-enabling the RAID function, but turned off the "Security/Freeze" option in the BIOS... and this time it made it to 31% and Froze with Drive 2 lit up.
So Now I am thinking this could be either a BIOS/MB or Backplane Issue... but that's enough for tonight... tomorow I will pull the machine and make sure all looks OK inside, Flash the BIOS and Try again.
What Fun!