Not to be presumptious, or rude, but I've read the first part of this thread (a bit late, yes) and I'm just confused.

If you're going to go so far as to prep the drive at home, before driving to the NOC, with a unrunnable OS on a labeled disk, it seems silly.

I propose:
Do a typical install of FreeBSD 6.4/7.1 on this disk. Let it be as full as to boot an operating system (but maybe skip out on the networking blah blah setups).
        Bring this (verified) bootable disk to the NOC, install it as da0
        Move the old, 73GB failing disk to da1
        Boot the Dell, maybe running in single-user mode
You've got a pristine format (or pristine enough) to restore the filesystems on top of it. Rebooting with da0 again to see if your network settings, startup, apps, etc etc etc all start as appropriate.

        Only if this method fails, do you use the Fixit CD and "fix it"

Am I crazy to think this is the more logical, more straightforward way to perform this migration? If Grant has already done the job, more power to him, but I just found it a little confusing that one would label a drive, format it, and possibly spend more time with the slower CD-ROM based Fixit than running off a nice, new 10k/15k RPM drive to drive everything.

If my method above is failing a point, I'd be more than happy to hear your statements and correct my procedures for it. My method above has only one tricky part, is to restore the 'a' partition from olddrive to newdrive. -- and that is probably a piece of cake.

Grant, good luck (if you haven't done it yet).

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