Got my replacement drive today. Trevor was home sick, so I didn't have any time to work on it until about 2 hours ago. Had a few problems buring the CD (bad batch of disks, or my drive isn't working), and finally went witht he floppy. Things worked fine after that.

The copy started off scary. With a ton of bad sectors. But it got past those, and is copying 76Gb over to the new drive. Using the rather complete Hinsdale instructions, From Any Single Drive Tivo to New Single Larger A Drive.

The old (bad) drive is still under warranty, so when I'm done copying data to the new drive, I just need to grab an error code,and get an RMA to get a new 80G drive. And no real idea what to do with it.