> My FreeBSD-4.9 setup uses one drive in "dangerously dedicated partition"
> where all of my partitions live in one slice:

That isn't what "dangerously dedicated" means.    It appears you
have a standard setup with just one slice of 4 used.   A dangerously
disk would have partitions of /dev/da0a, /dev/da0e, etc.

>       $ df
>       Filesystem  1K-blocks    Used   Avail Capacity  Mounted on
>       /dev/da0s1a     64462   37886   21420    64%    /
>       /dev/da0s1e     64462       4   59302     0%    /tmp
>       /dev/da0s1f    516062    6086  468692     1%    /var
>       /dev/da0s1g   2064302 1464672  434486    77%    /usr
>       /dev/da0s1h  10660096     720 9806570     0%    /data
>       procfs              4       4       0   100%    /proc
> I almost run out of space during a buildworld, so I'd like to expand
> /usr from 2 GB to 4 GB by taking space away from /data.  Since my
> filesystems will remain in the same slice, is it correct that I don't
> need to use fdisk(8)?

That would be correct.   But, you will need to use disklabel and newfs.

> So my procedure to do this is to recalculate the size/offset/cylinder
> settings for my partitions "g" & "h", change those settings via
> disklabel(8), then use growfs(8) on /dev/da0s1g?  Seems simple enough,
> and the data on /usr should be preserved, correct?

Yes and no.   I do not think you can shrink a partition with these.
Since, in order to grow /dev/da0s1g you will have to shrink /dev/da0s1h
I think you cannot do what you want.   I may well be wrong on this.
I haven't tried it.

If you really really must change those partition sizes, I would 
recommend backing them up with dump.  Then using disklabel to make
new sized partitions and newfs to make new  file systems and then
restore the two file systems.

My best recommendation, though, is to just move some of the big
stuff from /usr such as /usr/ports, /usr/local and /usr/src in 
to /data and make symlinks.   Probably tar is adequate for this.

  cd /usr 
  tar cvpf /data/ports.tar ports
  tar cvpf /data/local.tar local
  tar cvpf /data/src.tar src
  cd /data
  tar xvpf ports.tar
  mv ports usr.ports               // my naming convention
  tar xvpf local.tar
  mv local usr.local
  tar xvpf src.tar
  mv src usr.src
  cd /usr
  mv ports ports.old
  ln -s /data/usr.ports ports
  mv local local.old
  ln -s /data/usr.local local
  mv src src.old
  ln -s /data/usr.src src
Now check things out to make sure it looks good by cd-ing to
stuff like cd /usr/ports/www  or whatever and look to see that you
got to the right place   (/data/usr.ports/www)  and when you are
convinced, go back and clean up
  cd /usr
  rm -rf ports.old           // Watch for accurate typing here
  rm -rf local.old           // Also, if any files have flags set, you will
  rm -rm src.old             // have unset then with chflags(1)  as in
  cd /data                   //     chflags noschg file_name
  rm ports.tar               // in order to be able to rm them.
  rm local.tar
  rm src.tar

This should give you back quite a lot of your /usr file system
Although ports, local and src are the usual hogs, you may need
to use du in the /usr directory to find out what else is taking
lots of space if these aren't the ones.   Do you have a bunch of
home directories there or are you making them in /data for example.

> But will /dev/da0s1h be okay?  Is editing the disklabel enough?  Or do I
> need to reformat the partition --- and, if so, how?  I'm not too comfy
> using newfs(8) directly.  Can I just run "newfs /dev/da0s1h" after
> running the growfs(8) command and it will use the disklabel settings?
> Or can I be a wuss and use /stand/sysinstall?  :-)

Editing the disklabel will change the partition sizes.  
Definitely /dev/da0s1h will be messed up.   Running newfs on it
will build a new filesystem in whatever is now that partition.

> Any suggestions are appreciated, thanks in advance!

My above suggestion about moving some dirs is the biggie.


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