Humax T800 and InstantCake

So a week or so ago, my T800 harddrive fried - so much so that I couldnt even see it on my PC form the BIOS level. I got another harddrive and purchased the InstantCake software. Baked my cake no problem (tried this a few times - no errors). I throw the drive back in my Tivo and it gets past "Powering up..." to a solid light blue screen. Then nothing. Has anyone seen this before? I've tried all the mater / slave combinations with the jumpers, I've re-baked... dont know what else to try.

TIA,
Chris