Originally I tried doing a backup and restore onto a fresh installation, afetr a number or failed attempts I gave up on that and tried ghosting, which worked well apart from not resizing the partitions as you said. I then tried mondo archive which did resize the partitions, but none of the run level 7 services would start, so I was unable to connect to restor the /home backup I had created (as per how to). I then tried ghost again, ghosting each individual partition to the partitions mondo archive had made (/boot 200MB, /swp 512MB / remainder).
Am i misreading the mdstat file or is that showing the larger partition sizes compared to df?