Sleep? What's sleep? Yes. Yes. Drive enclosure? What drive enclosure? At this point the only thing active should be the TiVo. If you feel more comfortable, you can put the case hood on the frame, but there certainly is no need to screw all the screws back in to the case. You don't want the drive rolling around inside and shorting out things, either, so if you leave the drive in the drive mount, then I would screw in at least two of the screws to secure it. Alternately, you can wrap the drive in a piece of heavy construction paper and tape the paper in place to keep its metal parts from coming into accidental contact with the Tivo innards. Certainly keep your fingers and any conductive objects away from the inside of the TiVo while power is applied. Also be aware that when the TiVo is shut down, it can take some time for the filter capacitors on the power supply to fully discharge. After a few seconds the voltages will not be hazardous to your body if you touch them, but a conductive object like a screwdriver shorted across them can generate a flash large enough to cause a small burn or to destroy components inside the unit. Unless you know what's what, it's best to let the unit sit for 4 or 5 minutes after unplugging it before sticking a screwdriver in it. I expect it will, but let's not assume. If it doesn't, all is still not lost, but we will have to get a bit more creative. 'Worst case, you might have to shell out $20 for a copy of InstantCake. You might consider investing in an eSATA bracket like this, this or this for future utility. (Has anyone on the forum tried the third bracket out? It looks to be absolutely perrfect for use with an Antec MX-1 housing, if the power pin-outs are correct.) It sounds like you did. Correct. Supersizing can be done either before or after marrying the two drives. It's not part of the marriage process, and in fact it can be done before you remove the drive the first time, but I wanted to break the process down into small steps, checking along the way. The next time you get to the point where you are about to marry the two drives, look carefully at the WinMFS screen when you select the A (Upgrade) drive. It should look something like this: Well, I can't say what happened, since I was not there, but at a guess I would say despite your precautions, you accidentally got the drives swapped when selecting the primary and external drive. Don't feel foolish, if that's the case. I'm a professional engineer and I cannot count the times I have checked, double checked, and triple checked to make sure I had things in the right order, or polarities correct, or the safety in the correct position only to have the whole thing go ker-plewey because despite my checking it was not correct. After more than 30 years, it still happens to me all the time. Exactly. It's a little extra time, but it makes sure everything is correct to this point. Surely. In fact, if you re-read my post, you will see that is precisely my suggestion. No, not really. As long as the primary (Original or Upgrade) drive is plugged into the correct connector and properly powered, the TiVo should boot. Now it probably won't boot all the way up before it complains about an unrecognized external drive, but it should still boot. No, it won't harm the TiVo or physicaly harm the drives, but I suspect the formatting was munged by having the drives swapped in the PC when you married them. It's really not a huge deal either way, other than of course wasting your time. Not after they are married, no. Once they are married, both need to be present for the TiVo to boot up. It should not trash things, but the TiVo will complain about the missing External drive and refuse to boot unless you tell it to perform a divorcement. If you accidentally do, then you will have to re-marry the drives. The bottom line is no, I would not particularly recommend booting up only the Upgrade drive once it is married to the External drive.