Sounds like there may be a problem with the new drive. Is it brand new? Have you run diagnostics on it?

Hi, did you ever get this sorted? Having similar issue-

Series 3 TiVo- HDD died.

I got the "virgin" MFS file and burned it to an ISO9660 DVD
Purchased a Seagate 500GB HDD SATA
Tried two or three different boot CDs. Here's my process & results, maybe missing something:

Boot
mount /CDROM
execute: restore -s 127 -zxip /cdrom/tivo.mfs /dev/hdc

Every time it blows up with some type of space-related issue. SO I also tried the following:
Ran FDISK with defaults to create partition (then rebooted)
used mke2fs and mkreiserfs with defaults to format the partition.

Every time I try the restore, it removes the partition & format but dies right away. What am I missing? Thanks.

Please note the DVD has the .MFS file on it, and this is a brand new HDD. I don't see this scenario covered in Hinsdale or with any of my searching.

I'm wondering if having the .MFS file on DVD is what is causing the issue? Do the restore tools try to expand or write some temp data on the source disk? That's what appears to be happening, since the destination clearly is available for writing.

You should be able to restore from a DVD-based image file.

What's the exact error message?

I'm doing this manually, not using Instantcake, but this is the point that the restore is failing. I'll post the error message verbatim tonight, it's something along the lines of "backup has insufficient space"