Well since I was not able to recover a workable image from my dead drive, I decided to abandon trying to recover my programs and just restore my tivco from a virgin image file.
I downloaded Instantcake IC2-SVR3000-7.2.0-oth-01-2-110.iso , booted it on my Core Duo Imac, and "baked" to a 12 GB virtual HD mapped to /dev/hdc without expanding. I then I attached my new 320 GB Seagate Barracuda ST3220620A drive, using an external usb2.0 enclosure, rebooted into Ubuntu, and did
mfsbackup -f 9999 -so - /dev/hdc | mfsrestore -s 127 -r 4 -xzpi - /dev/sda
When I started up my Tivo, I got no startup animation or backgrounds. and after doing guided setup I would get random reboots when navigating the menus.
I downloaded ptvlba48-4.04DD.iso, and booted from it. then I modified the script in /bin/PTVbake-special to use /dev/sda, and I "baked" directly to
the external 320 GB drive, using the options to expand and create 127 mb swap. This took over 3 hours and gave me the same results as attempt 1
Using PTVbake-special on the ptvlba48-4.04DD, I baked to the virtual /dev/hdc, without expanding or creating a 127 MB swap.Then rebooted into Ubuntu, and did
mfsbackup -f 9999 -so - /dev/hdc | mfsrestore -s 127 -r 4 -xzpi - /dev/sda. the results were the same as attempt 1 and attempt 2
Can anyone see anything I'm doing wrong, or can I conclude that the problem is a bad backup image on the Instantcake CD.