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DirecTivo Upgrade and Mfs Tools 2.0 Problem
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Posted by: Robert Y

A few problems as I tried to upgrade my DirecTivo DSR6000 to larger A and B drives. I first found that I could not get either of the "boot CD" versions (earlier or the one listed for Mfs Tools 2.0) to actually boot. I received the message "isoLinux 1.6.2 2001-04024 isolinux: Failed to get sector size, assuming 0800 isolinux Disk error01, drive FF. Not having any Linus experience, I gave up on the boot CD at this point.

I was able to use Tiger's Mfs Tools Boot Floppy (for Version 2) and followed the instructions in the hinsdale paper, Step 7 Option 2 in order to backup both original Tivo drives. However, when backing up the two drive configuration, I noted a series of messages "mfs_read_inode: Inode XXXXXX corrupt, trying backup" where the XXXXXX was a set of increasing numbers. At the end, the Mfs Tools report did indicate original image size and a new (larger) resulting inage size as the hinsdale paper described. Since I was replacing both drives and did not need to write to the orginal drives, I decided to proceed with combined restore and expand as suggested in Step 8.

During the restore and expand operation, I got similar message traffic as in the backup, but it did indicate expanded hours at the end of the process. I then placed place the new drives in the Tivo box and have not gotten out of "powering up" after letting it run during the remainder of the night (which was a little shorter than I had hoped).

I plan to do the suggested checks of IDE configuration tonight. The original Tivo Quantum drives had A jumpered as CS and B w/o jumpers and I used the same configuration for the new WD 120G drives. I plan to see if jumpers as Master for A and Slave for B make a difference, as well as checking if there was any way I could have installed them reversed, etc.

I do note that the earlier hinsdale paper made a point of using a different floppy configuration (DTivoMad4.0) for the DirecTivo units. I didn't see any similar distinct directions in the Mfs Tools 2.0 related discussion on creating a boot for floppy. If the above does not work, I plan to drop back to that path. More later...

Posted by: Robert Y

Continuing the story in my first message.

After getting the error messages in the MFS Tools 2.0 backup and restore, I then tried the backup and restore in MFS Tools 1.1. The backup ran without error messages and so did the DirecTivo floppy setup (using all 13 disks). However, I still could not get anything to work. the TIVO box seemed to be doing periodic disk seeks, but nothing that sounded like it was in any form of control. I then tried using drive ID by jumpers (the original Quantum drives were A = CS and B = no jumper) since I had initially set up the new Western Digital drives indicating the same cable sense capability . However, when I jumered the new drives for A = Master and B = Slave, it actually did try to load software, the TV screen flickered, etc. A definite improvement, but still not too effective for watching TV.

Before abandoning the upgrade and going back to the original drives (at this point very glad I had saved both original drives in the virgin form), I decided to make one more attempt. My thought was that the initial restore using a corrupt TIVO.bak with MFS Tools 2.0 might have prevented the MSF Tools / TIVOMadd restore from working. Very glad I did try this approach, as everything is now working just fine, with the system indicating 225+ hours of time. Therefore, my success used MFS Tools 1.1 to do the backup and MFS Tools 2.0 to do the restore.

Observations:

The Western Digital Caviar 5400 RPM 120 GB drives are perhaps slightly louder than the Quantum drivers, but not objectionable. I regret that I did not know that the system information screen contained a temperature reading, since the box had seemed very warm with the original Quantum drives. The WD drives indicate slightly lower power requirement on the label, relative to the Quantum drives. The operation with the WD drives seems slightly cooler, with system information screen indication of 52 deg C (comment is "good" or something like that). Since I work in aerospace I have lots of good experience with electronics running at high temperature, but I do have concerns about hard drive reliability. Yet another reason to preserve the original drives, in case I ever have to do this again.

I purchased my Western Digital Caviar 5400 RPM 120 GB drives at Fry's during one of their periodic sales. I was somewhat amazed to find that the drives I purchased in Los Angeles on 17 Jun 2002, carried a manufacturing date of 27 May 2002 on the label, ESD foil bag labeled May 02, etc. Impressive logistics chain!

Final suggestion: Check the floppies via scan or format before using the "rawrite" utility to record the images, if you can't get the CD boot to work. I normally don't use my old computer with DOS / FAT or floppies very much any more, obviously I had some degradation in iether the floppy drive or the floppy disks. I had several bad ones and was glad I caught them before I did any damage.