A tip of the hat to Mr. Sleeper for a very fine utility!!
I finally got an extra hard drive to give the Sleeper ISO (V1.02) a try and it performed flawlessly on my enlarged (to 120GB) but yet unhacked HDVR2 running V3.1.1b. My console port came up with trash (am using old dumb terminal instead of PC port) so I'll need to modify the port speed.
I installed the MONTE'd extra drive back in the Tivo and didn't connect a TV set... I just let it chug a bit and when the light came on my USB/Ether adaptor I went to another PC and was able to Telnet and TivoWEB just fine!
Re: setting partitions
FYI, I use a partition utility (at no cost) that is a subset of a product called "BOOTIT NG" (http://www.terabyteunlimited.com/bootitng.html), which is a 3rd party multiboot tool (cost: $34.95). If you follow their instructions you end up making a floppy disk that you can use to install their product. If you just click 'cancel' so as not to let it install anything it dumps you out into a window in which you can click "partition work" and you can make FAT32, NTFS, Linux EXT2, etc. partitions to your hearts content.
Using this partition tool doesn't cost anything - the cost comes in if you install their multiboot tool - it works normally for the "trial period" but after that it gets ever s-l-o-w-e-r in rebooting your system until you pay up and install the unlock code.
There are lots of other partition tools, some of them are listed at this particular partition tool site: http://www.ranish.com/part/