I don't know who in the future this might benefit, but if you have a #Buffalo #TeraStation NAS device, and you're trying to replace a failed drive, you are *not* supposed to format the new disk before beginning the RAID Recovery process.
If you *do* format the new disk (haha oops), and the "Recover RAID Array" button just stays greyed-out, try unmounting and ejecting/reinserting the new drive. It should come back up as Unformatted, and you can use it to recover the RAID volume.
#storage