> - put the replacement drive into an empty bay
> - clone /dev/sda onto it like: dd if=/dev/sda of=/dev/sdc
> - move the new drive into the /dev/sda drive bay
>
> Or is there another preferable solution?

This is almost the _worst_ solution, as dd deals with all the blocks
on the disk, including blocks not used by the file system (i.e. free
space) that you don't need to copy;  and it will also  copy a
filesystem in a possibly inconsistent state (especially if, during the
copy, some process is doing a lot of I/O on the file system)

It's far better to do a copy from old to new using a live dvd (in
order to work on a cleanly unmounted and not write accessed disk); if
you are in a real hurry, you could start doing a copy (at file system
level, i.e. cp) from old disk to new disk, and then later synchronize
it (e.g. re-copying all files changed from the first cp command).

If you have an LVM backed file system, and some spare space, you could
do a snapshot of the file system with all services stopped, and then
copy the snapshot: it could hang your system if you are using an RHEL
older than 5.X (guess X it's about 4, not sure) when you snapshot the
/ partition, but otherwise it will give you the best of both world
(consistent file system view and reduced downtime)

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