Hi Mark,
Can anyone provide some advice on that I am missing conceptually?
Several issues. First, if you use 4k blocks, the max filesystem size for ext3 is 16TB (see wikipedia on ext3). Second, I can't remember where, but on some filesystem tool's manpage, I read that the tools have problems going over 16TB. Third, fsck on a 16TB filesystem will take *days*, literally. I'm setting up, right now, a humongous RAID box, and I'll probably be divvying up the 42TB (mirrored!) as 3 14TB filesystems, and they're going to be ext4.
16tb is the max I would have for this device.
Jason