OK, here is the short version. Had weaknees series 2 by Tivo (model TCD240040) with a 40g and 120g drives. The 120g drive died. I started from scratch using InstantCake with 2 new Western Digital 160g drives. My Tivo is now happily up and working with software version 7, and after doing a "clear and delete everything" to correct the error #51 which prevented it from recording, it now works beautifully.
The only problem is that I get about 322 hours due to the 137g limit instead of about 415 hours.
What is the EASIEST way to max out both drives to the full 160g???