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problem solved - beware

Problem solved....

The drive acts just like it did during the TEST run! I was thinking about that along with the fact that I have a 45 GIG drive in my PC. CRAP!!!! I wrote the copy/expand to my PC drive! Sure enough, I tried booting the PC and got a boot error. Put the PC drive in the Tivo and there it was. Reported 39 hour record time (extra 5 gig space) and played all old programs.

Now I can't take the ENTIRE blame (sure some of it was my fault for not checking each step). But at the beginning of the hinsdale how-to document, they define the default IDE connections

hda - pc FAT32 C: drive
hdb - primary slave - new bigger single drive
hdc - secondary master - old tivo drive
hdd - secondary slave - cd cd-rw drive

those settings worked fine for the backup and test steps. But when you perform the copy/expand command for a single to single drive (slow option):

mfsbackup -Tao - /dev/hdc | mfsrestore -s 127 -xzpi - /dev/hda

YOU END UP WRITING TO THE FAT32 PC DRIVE!!!!

Well I should have looked at the boot script to varify the drive settings.
Luckily I didn't use my new XP computer, but was using the old Windows-ME computer. I don't think I lost anything important.

Thanks for the help!
Everyone beware!