This one is easy: Learning that RAID 0 sucks... the hard way.
Picture this, I built a top-of-the line system with a pair of Raptor 10K 150GB drives in RAID 0, with another 740GB in a JBOD array. For six months I used this system for both work and play and had accumulated TONS of important work-related applications (many with hardware-tied DRM schemes). Unfortunately, backing up this system to a 1GB WD extrenal HD took over 24 hours! That meant that all day, every day, the backup was running. This became untenable during a work project where I was working 90+ hours a week on the computer. Suddenly, it happened. A Raptor failed. Being RAID 0, the OS was toast, unless I could restore the backup. But first, I had to get another Raptor to rebuild the array. Unable to wait for WD to get around to sending me a new drive, I order one from New Egg with next day delivery. I get the drive the next day and start to rebuild the system. Uh, oh. The external 1GB drive had run out of space and the last 3 backups were toast. Problem was, 3 was to number of backups that I had space for and thus ALL backups were toast.
So, I decided no more RAID 0. I order another Raptor from WD, giving me 3. I set up the three drives in a RAID 5 and reinstall Vista, and then spending DAYS reinstalling software, including many hours of waiting on hold to get authorization to re-register software. And let's not count the time it takes to configure said software. All-in-all I lost an entire week to this.
But it's not over. The day after getting the system back up to workable specs, the second of the original Raptors died. Having learned my lesson and going with RAID 5, this wasn't a tragedy, but I had yet to receive my RMA on the original failed drive, so back to New Egg I go. I repair the array and send back the second failed drive to WD. A couple of days later I get a replacement drive from WD. Murphy, who has been laughing at me for weeks now, took the opportunity to kill one of the new drives. Back to repairing the RAID 5, this time with the RMA drive. So, I send yet another drive to WD for RMA. By this time I know am the proud owner of five Raptors. When the other drive finally come back via RMA I put it aside as a spare. Everything was fine, for about six months, then the first RMA drive died, and my spare goes into the RAID 5. The RMA drive gets RMA'd, and I am back up to 1 spare drive. This process has repeated itself EVERY SIX MONTHS since then. Last time was in January 2009. Uh oh, it's almost July. 🙁
This was an expensive lesson, another $600 in additional drives, plus the discovery that I needed an enterprise level backup solution. This precipitated the purchase and configuration of a quad-core file server with it's own RAID 5 array of four 750 GB drive yielding a 2 TB storage array. It also required upgrading all my switches to 1 GB so that backups could complete in a reasonable amount of time (although it still takes about 18 hours for the weekly full backup). Total tally, $3000 and at least 2 weeks of lost work time.