I thought I'd update the thread on what happened. I went back to his house and he was pretty anxious to get the drives tested so instead of running a 6 hour consistency check and coming back the next day I thought I'd at least run a quick test on the drives. I pulled them both and hooked them up to my laptop via a USB/SATA adapter and ran Seatools. I ran the short test and the first drive pass with no problem and when running the tests the progress bar went smoothly and quick. When I hooked up the second drive the progress bar would go smoothly for a second then pause then continue erratically. It failed. I tested both drives two more times just to be sure there wasn't a problem with my USB adapter and the results were consistent, the bad drive failed every test and the good drive passed no problem.
Here is where I may have made a mistake... since these were internal drives there was no way to set the PERC software to flash the lights on the drives to identify them. I didn't think to follow the cables and see if they were labeled on the PERC until later. So I didn't mark the bad drive as OFFLINE and just booted up with the good drive by itself. Of course I got an error saying the mirror was degraded but it booted Windows and you could see an immediate change. Instead of Explorer crashing every 30 seconds and freezing up it ran just fine. When he launched his photo editing program it did freeze up while loading thumbnails. It was getting late so I set chkdsk to run at boot and rebooted, hoping chkdsk would fix any file problems on the drive. I left it and called the next day and he said everything seems to be running fine and I haven't heard from him since so I guess that's a good thing.
He still had a month left on his extended warranty with Dell so I called them up and got a replacement coming tomorrow.
My question now is, since I didn't mark the bad drive offline, will I still be able to just throw another drive in and rebuild the mirror or will I have to image the good drive, delete and logical drive, and recreate a new mirror then reload the image? Or will I be able to install the new drive and add it back to the mirrored set? I've been reading the PERC 6i manual on Dell's site and it doesn't really say if I didn't mark the drive as offline.