Restored backup does not expand

[Steverino]

I'm trying to restore my Phillips Series 1 single drive Tivo from a backup I made with MFSTOOL 2.0. The restore appears to work fine, but it doesn't expand to fill the capacity of the hard drive. At the end of the restore command this message appears:

Restore done!
Adding pair /dev/hdb12-/dev/hdb13
New estimated stand alone size: 33 hours (3 more).

The hard drive is 160GB and I'm booting off of a LB48 CD. Mfsinfo confirms the 33 hour size and says the drive may be expanded 4 more times. The TiVo's original hard drive was a 30GB. I'm using the -x option, so why isn't the backup expanding to fill the drive? I've tried three different backup files including my original TiVo backup. I've also tried two different LB48 boot CDs.

I originally upgraded the single 30GB drive to a single 160GB drive. I later upgraded the 160GB drive to a 250GB drive. I made backups before and after each upgrade. The 250GB has worked well for the last seven months, but it "died" yestesday(probably because it's an IBM DeathStar). I've returned this drive for a replacement under warranty, but it will be weeks before my replacement arrives. In the mean time, I'd like to use the 160GB drive that I had used before.

Here's what I'm doing:
Connect a FAT32 drive containing my backups to Secondary Master IDE (hdc)
Connect the CD drive containing the LB48 boot CD to Secondary Slave IDE (hdd)
Connect the 160GB hard drive to Primary Slave IDE (hdb)
Boot off the LBA48 CD and run the following commands:
# mkdir /mnt/dos
# mount /dev/hdc1 /mnt/dos
# mfsrestore -s 256 -xzpi /mnt/dos/backupFile /dev/hdb

The restore process appears to work fine, but does not expand to fill the drive. I've also tried the mfsadd command but it says there's nothing to expand. I've also tried running the copykern command before expanding but that didn't make any difference. What am I doing wrong?

Thank you,
Steve Smith

[Jamie]

How sure are you that the drive was recognized by linux as a 160GB drive? If you look through the kernel messages (e.g. with dmesg), look for where the drive was identified. You should see something like this:bash-2.02# dmesg | grep hdb
hdb: ST3160021A, ATA DISK drive
hdb: 312581808 sectors (160042 MB) w/2048KiB Cache, CHS=19457/255/63 In my case, a 160GB Seagate model ST3160021A.

If it isn't being recognized as a 160GB drive, carefully check the jumpers. There is sometimes a jumper that forces drives to declare themselves smaller than they really are, for compatability with legacy bios code. Reference (http://www.pcguide.com/ref/hdd/bios/overJumpers-c.html).

[Steverino]

How sure are you that the drive was recognized by linux as a 160GB drive? ... If it isn't being recognized as a 160GB drive, carefully check the jumpers. That was the problem! My Samsung's jumper was accidentally set to limit it to 32GB. Thanks so much! I had posted this problem in TiVoCommunity's forum earlier this afternoon and apparently everyone was stumped. You came up with the answer right away. Maybe now I'll still have time to use my TiVo tonight to record Survivor and The Apprentice.

Thanks again,
Steve Smith