I know this question has been asked before, and I apologize for repeating, but I've not yet seen an answer that solves this particular situation.  I upgraded my Phillips DSR6000 from a single 40GB to a dual (80GB + 40GB) some years ago.  I'm now trying to consolidate both drives to a single 250GB.

Following the directions in Hinsdale and Weaknees' Interactive Upgrade, I booted up with LBA48 Boot CD I purchased from DVRUpgrade with both old and the new HDs.  I ran the command:

 mfsbackup -Tao - /dev/hdb /dev/hdd | mfsrestore -s 127 -xzpi - /dev/hda

 to backup up with programs.  I keep getting the "Insufficient space on destination drive" error, even though the new drive is over twice the size of the old two combined.  If I run:

 mfsbackup -Tao - /dev/hdb /dev/hdd | mfsrestore -s 127 -pi - /dev/hda

and don't try to expand to the full size of the new drive, that works (experimenting with different combinations, I found that the "x" on the restore is the issue), but doesn't expand the new drive to its full capacity, it just shows the capacity of the 2 old drives.

I've tried MFSadd, but it just tells me that it would result in too many partitions.  According to MFSinfo, there are only 6 partitions, and the volume can be expanded 3 more times. 

Any ideas?  I'm stumped...

Thanks!