So, we had a power outage, then the DTivo wasn't coming back up.  Wasn't finding the hard drive.  I took the drive out, ran Maxtor's diag util on it (120G ATA drive), and the util indicated that the drive is failing and it should be replaced.  Not surprising.

There is also a 20G hard drive in there because I had it on hand when I did my first upgrade.  It also has a NIC I haven't used in a couple of years.

I found the Instantcake image and that seems to address most of what I need.  I need a new hard drive, probably a second since a 20G is almost pointless.  The Instantcake image says it will set up a two drive system, great.  It references that it will set up the NIC, cool.

It also says that it is tested with up to 500G drives... I remember a limitation in the controller from when I did the first upgrade that it could only handle something like 135G... has this changed?  Does the new software have updates that let it handle really big drives?  I wouldn't mind dropping a couple 200G drives in there.