So I finally managed to get the disk formatted to 512 with in an external enclosure, and they seem fine there (and 0% usage on them, so great), but they still fail to be recognized by my raid card! Could it be they are incompatible with 12Gbs cards?
The bizarre thing is that megacli still claim it is 520 sectors, while, it isn't it was formated (and verified) in the other enclosure... SO my guess is that, it's 'guessing'...
w Size: 0 KB [0x0 Sectors]
Non Coerced Size: 0 KB [0x0 Sectors]
Coerced Size: 0 KB [0x0 Sectors]
Sector Size: 520
Logical Sector Size: 520
Physical Sector Size: 4160
Firmware state: Unconfigured(bad)
Device Firmware Level: EQPC
Shield Counter: 0
Successful diagnostics completion on : N/A
SAS Address(0): 0x5002538a06a725e2
SAS Address(1): 0x0
Connected Port Number: 5(path0)
Inquiry Data: SAMSUNG P1633N38 EMC3840EQPCNZNA0HA02469
FDE Capable: Not Capable
FDE Enable: Disable
Secured: Unsecured
Locked: Unlocked
Needs EKM Attention: No
Foreign State: None
Device Speed: Unknown
Link Speed: Unknown
Media Type: Hard Disk Device
Drive: Not Supported
Drive Temperature :34C (93.20 F)
PI Eligibility: No
Drive is formatted for PI information: No
PI: No PI
Port-0 :
Port status: Active
Port's Linkspeed: Unknown
Port-1 :
Port status: Active
Port's Linkspeed: Unknown
Drive has flagged a S.M.A.R.T alert : No