I have searched many threads and tried several combos, so thanks for taking the time to read my post.
I've just replaced two disks (40G + 100G) on my S1 DTivo, combining them with the mfslive CD onto a single 300G. Following the procedure on the mfslive site didn't work, so Spike helped me out. He suggested I do the combination first using the CD without expanding to use all of the space on the new drive, and then expand with mfsadd on WinMFS.
That all worked out fine.
Of course, when the disk was expanded beyond 137G I needed to replace the kernel. I did this using the LBA48 CD, mounting the CD first and then using copykern (I selected the 3.10+ kernel).
So far, so good. Except that I get spurious reboots. My TiVo has a cachecard in it and runs TiVoWebPlus. After a few minutes of use it randomly reboots. The cachecard appears to be working just fine (at least the driver loads without problem).
Is there something I'm doing wrong? There is a note at the start of the LBA48 CD thread talking about doing a killinitrd, but I'm not sure why that would apply.
For now, I am running without doing the expansion (and, without replacing the original kernel) limiting space to 137G and everything is great - no reboots.
Am I missing an important step along the way?