Failed Drive in SA 642

Some help would be greatly appreciated.
Here's the scenario:
HP DL145 G2
SA 642 + BBWC
2x36GB (RAID 1)

Running out of space on the drives so I:
1. Removed one drive (1/2)
2. Set to failed
3. Inserted new larger drive 72GB (3/2)
4. Rebuilt array
5. Removed 2nd drive (2/2)
6. Will not rebuild
7. Reinstalled drive (2/2)
8. Rebuilt array
9. Shutdown and added larger drive (3/2) as spare
10. Confirmed array was good and removed drive 2/2
11. Activated hot spare and rebuilt

Problem I have is that I can't remove the failed drive from the ACU (see attached) as I now have the server how I want it.
I want to make the active spare as part of the array and not a active spare.
I worked on this for 9 hours without resolution. Scheduled maintenance was only 2 hours.

Thanks in advance.