"As far as the instructions go for copying the settings and programs, I am assuming the "expand" command is done in the jmfs environment but I will still need to come back to winmfs in Windows to execute "supersize" before I install the new drive." Correct, although you can go ahead and supersize the 1TB Hitachi with WinMFS first and then copy it to the 2TB with jmfs and add the 16th and final partition with jmfs. Supersizing uses some of one of the original factory TiVo partitions and "unreserves" it, so you can do it anytime. Apparently at least in part because of the CPU used in the original Series 1, TiVo chose to use the old Apple Partition Map way of formatting a hard drive, or at least a version of the APM. The first partition of an Apple Partition Map formatted drive is always the partition map itself, regardless of what it's used in.