Hi all. Before I ruin my new Seagate 160GB laptop drive I want to ask the experts here for some advice. Laptop: Dell Inspiron 6000, July '05. Original 40GB IDE drive had Dell diagnostic partition, Dell system restore partition & C partition with XP Pro, etc. NO MEDIA DIRECT. I'm using TI9 v3677 and I have a good 40GB drive image saved on my external drive. The 40GB drive is dead and buried. Objective: To install the new Seagate 160GB drive into the laptop and to keep the Dell diagnostic partition, Dell system restore partition & C partition with XP Pro except to expand the C partition to fill the 160GB drive. Problem: I know that I can simply restore the image of the 40GB drive onto the new 160 drive but the C partition will still be approx. 35GB. I cannot increase the partition size or the MBR will change and break the Dell system restore function. But, if I do a Dell system restore after installing the 40GB image onto the 160GB drive, it will create a new C partition and fill the new drive like I want it. The problem is that TI9's restore image operation will carry over any bad sectors that may have existed on the old 40GB drive and map them out on the new 160GB drive even thought they may not actually be bad. AGain, I cannot restore the image to the new drive and increase the size of the C partition or the Dell MBR will change and I will end up with a broken Dell system restore function. If, instead I want to clone to the new 160GB drive to get around the bad sector carryover issue, I have to buy a new 40GB drive to restore the Dell 40GB drive image to. That's too costly. I'm not savvy enough to follow Dan Goodell's Dell system restore fix process. I'll screw that up. So, I can't restore the 40GB drive image to the new 160GB drive, change partition size, modify MBR and then fix it. I'm just not that good. As a test, I restored the 40GB drive image to the new Seagate 160GB drive and expanded the C partition, restoring each partition in the correct order (diagnostic first, C expanded second, system restore third and finally the MBR). When I restarted, I got the missing Hal.dll file stop screen. I don't know Hal and I don't know how to fix that either. Can anybody lead this horse to water so I can drink? I know there's someone here a lot more savvy than me who could do this with his eyes closed. What am I missing? Help, please!