40+120 to 160 copy failed

[cp1cp2]

I have a Series 1 DirecTivo that currently has an A+B configuration with A=40GB and B=120GB. I am trying to copy (while saving recordings) the two drives to one 160GB drive. I've tried the following commands to no avail:
mfsbackup -Tao - /dev/hda /dev/hdb | mfsrestore -s 127 -xzpi - /dev/hdd
mfsbackup -Tao - /dev/hda /dev/hdb | mfsresote -zi - /dev/hdd

In each instance I get the following error:
Source drive size is 30 hours
- Upgraded to 39 hours
- Upgraded to 79 hours
- Upgraded to 177 hours
Uncompressed backup size: 152060 megabytes
Restore failed: Backup target not large enough for the entire backup by itself.

When I check the boot screens hdd reports 160042 MB which is obviously larger than the uncompressed backup size of 152060.

Is there anything I can do, short of buying a larger drive, while keeping my recordings? Would dd work in this instance? If so, what is the appropriate command? I've read that dd can be destructive and I don't want to use the wrong command.

cp

[eastwind]

If you haven't hacked for extraction (mfs_ftp) you probably won't be able to save your recordings. More information is needed before offering more advice. What is the reason for this move to a single large disk?
Are you using an LBA48 aware linux environment (kernel) on the PC and on the DirecTiVo? If everything isn't just right (looks okay on the PC side) you can really get into a fix.
What boot CD are you using (if you are indeed using one)? Some have issues with byteswapping especially on /dev/hda.
What is the output from mfs_info? (Could be out of mfs pairs.)
What is the output after booting the PC from dmesg | grep hd? (Show what it found for hard disks.)

Generally the more information you can provide, the easier it will be to help you with your problem.

If you have hacked for extraction you could ftp the shows you really want to keep and then move them back after getting the 160 up and running.

Have you tried to minimize the fileset? Check the readme in mfstools to see what the command is and whether you can use it with saving recordings or not.

ew