On 25/07/2024 at 00:11, Brian J. Murrell wrote:

After having created the new partition and copying the existing boot
partition's contents to it and then mounting the new partition on /boot
and editing /boot/grub2/grub.cfg to change all of the "msdos5"
references to "msdos7" (to reflect the new partition)

You should have regenerated grub.cfg with update-grub(2) instead.

I went ahead and did a:

# grub2-install --root-directory /boot /dev/sda

It should be --boot-directory (or nothing, as /boot is the default).
--root-directory is an obsolete hidden option which sets the target root directory. So I guess you installed GRUB in /boot/boot/grub and $prefix is set to (hd0,msdos7)/boot/grub.

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