Hi. Sorry it took so long to reply.
First, idp_qbn: Thanks for your suggestion. I chose not to go the AFFA route because I had spent time understanding the Upgrade Disk process and was reasonably familiar with it. Once I understood it it seemed, and was, pretty straight forward...except it didn't seem to work for some reason. That's what I'm trying to sort out here.
Mary, Cacutus
Here's info from my system. I don't see anything that looks strange, but then I'm not that knowledgeable so maybe you folks'll pick something up. I perused the messages file but nothing jumped out at me...then again...
Here's the history of the Upgrade Disk commands. I left all commands in, even the goof ups just in case they are significant.
383* mount /dev/hda3 /mnt/tmp/[B
384 ls hda3
385 ls /mnt/tmp
386 fdisk -l | less
387 mount -t vfat /dev/sdc /mnt/usb
388 mount -t ntfs /dev/sdc /mnt/usb
389 mount -t fat32 /dev/sdc /mnt/usb
390 mount -t vfat /dev/sdc1 /mnt/usb
391 cd /mnt/usb
392 ls
393 fdisk -l | grep hda > hdafdisk.txt
394 less hdafdisk.txt
395 umount usb
396 umount sdc1
397 umount /mnt/usb
398 cd ..
399 umount /mnt/usb
400 db configuration setprop backup Progam CopyFromDisk status enabled
401 signal-event pre-restore
402 ls /mnt/tmp
403 signal-event restore-tape /mnt/tmp
404 ls /mnt
405 fdisk -l | less
406 df -h
407 cd /etc/e-smith
408 mv templates-custom templates-custom.old
409 mkdir templates-custom
410 mv templates-user-custom templates-user-custom.old
411 mkdir templates-user-custom
412 signal-event post-upgrade
413 signal-event reboot
Here's the old server disk info:
ls /mnt/tmp
aquota.group
aquota.user
bin
boot
command
dev
etc
home
initrd
lib
lost+found
media
mnt
opt
package
proc
root
sbin
selinux
service
srv
sys
tmp
usb
usr
var
fdisk
Disk /dev/hda: 250.0 GB, 250059350016 bytes
/dev/hda1 * 1 288 2313328+ 83 Linux
/dev/hda2 289 831 4361647+ 82 Linux swap
/dev/hda3 832 30401 237521025 83
Info about sda, drive one of new server.
Disk /dev/sda: 1000.2 GB, 1000204886016 bytes
/dev/sda1 * 1 13 104391 fd Linux raid autodetect
/dev/sda2 14 121601 976655610 fd Linux raid autodetect
Oct 18 14:15:14 cherubim kernel: SCSI device sda: 1953525168 512-byte hdwr sectors (1000205 MB)
Oct 18 14:15:14 cherubim kernel: SCSI device sda: drive cache: write back
Oct 18 14:15:14 cherubim kernel: SCSI device sda: 1953525168 512-byte hdwr sectors (1000205 MB)
Oct 18 14:15:14 cherubim kernel: SCSI device sda: drive cache: write back
Oct 18 14:15:14 cherubim kernel: sda: sda1 sda2
Oct 18 14:15:14 cherubim kernel: Attached scsi disk sda at scsi0, channel 0, id 0, lun 0
Oct 18 14:15:14 cherubim kernel: md: bind<sda1>
Oct 18 14:15:14 cherubim kernel: md: bind<sda2>
Oct 18 14:15:14 cherubim kernel: md: could not bd_claim sda1.
Oct 18 14:15:14 cherubim kernel: md: could not bd_claim sda2.
Oct 18 14:20:55 cherubim kernel: SCSI device sda: 1953525168 512-byte hdwr sectors (1000205 MB)
Oct 18 14:20:55 cherubim kernel: SCSI device sda: drive cache: write back
Oct 18 14:20:55 cherubim kernel: SCSI device sda: 1953525168 512-byte hdwr sectors (1000205 MB)
Oct 18 14:20:55 cherubim kernel: SCSI device sda: drive cache: write back
Oct 18 14:20:55 cherubim kernel: sda: sda1 sda2
Oct 18 14:20:55 cherubim kernel: Attached scsi disk sda at scsi0, channel 0, id 0, lun 0
Oct 18 14:20:55 cherubim kernel: md: bind<sda1>
Oct 18 14:20:55 cherubim kernel: md: bind<sda2>
Oct 18 14:20:55 cherubim kernel: md: could not bd_claim sda1.
Oct 18 14:20:55 cherubim kernel: md: could not bd_claim sda2.
Oct 19 19:53:30 cherubim kernel: SCSI device sda: 1953525168 512-byte hdwr sectors (1000205 MB)
Oct 19 19:53:30 cherubim kernel: SCSI device sda: drive cache: write back
Oct 19 19:53:30 cherubim kernel: SCSI device sda: 1953525168 512-byte hdwr sectors (1000205 MB)
Oct 19 19:53:30 cherubim kernel: SCSI device sda: drive cache: write back
Oct 19 19:53:30 cherubim kernel: sda: sda1 sda2
Oct 19 19:53:30 cherubim kernel: Attached scsi disk sda at scsi0, channel 0, id 0, lun 0
Oct 19 19:53:30 cherubim kernel: md: bind<sda1>
Oct 19 19:53:30 cherubim kernel: md: bind<sda2>
Oct 19 19:53:31 cherubim kernel: md: could not bd_claim sda1.
Oct 19 19:53:31 cherubim kernel: md: could not bd_claim sda2.
Info about sdb, second drive of new server
Disk /dev/sdb: 1000.2 GB, 1000204886016 bytes
/dev/sdb1 * 1 13 104391 fd Linux raid autodetect
/dev/sdb2 14 121601 976655610 fd Linux raid autodetect
Oct 18 14:15:14 cherubim kernel: SCSI device sdb: 1953525168 512-byte hdwr sectors (1000205 MB)
Oct 18 14:15:14 cherubim kernel: SCSI device sdb: drive cache: write back
Oct 18 14:15:14 cherubim kernel: SCSI device sdb: 1953525168 512-byte hdwr sectors (1000205 MB)
Oct 18 14:15:14 cherubim kernel: SCSI device sdb: drive cache: write back
Oct 18 14:15:14 cherubim kernel: sdb: sdb1 sdb2
Oct 18 14:15:14 cherubim kernel: Attached scsi disk sdb at scsi2, channel 0, id 0, lun 0
Oct 18 14:15:14 cherubim kernel: md: bind<sdb1>
Oct 18 14:15:14 cherubim kernel: md: bind<sdb2>
Oct 18 14:15:14 cherubim kernel: md: could not bd_claim sdb1.
Oct 18 14:15:14 cherubim kernel: md: could not bd_claim sdb2.
Oct 18 14:15:16 cherubim esmith::event[3699]: Running event handler: /etc/e-smith/events/bootstrap-console-save/S03conf-hostsdb
Oct 18 14:15:16 cherubim esmith::event[3699]: S03conf-hostsdb=action|Event|bootstrap-console-save|Action|S03conf-hostsdb|Start|1287425716 847628|End|1287425716 924002|Elapsed|0.076374
Oct 18 14:15:49 cherubim smbd[5315]: [2010/10/18 14:15:49, 0] passdb/pdb_smbpasswd.c:startsmbfilepwent(241)
Oct 18 14:20:55 cherubim kernel: SCSI device sdb: 1953525168 512-byte hdwr sectors (1000205 MB)
Oct 18 14:20:55 cherubim kernel: SCSI device sdb: drive cache: write back
Oct 18 14:20:55 cherubim kernel: SCSI device sdb: 1953525168 512-byte hdwr sectors (1000205 MB)
Oct 18 14:20:55 cherubim kernel: SCSI device sdb: drive cache: write back
Oct 18 14:20:55 cherubim kernel: sdb: sdb1 sdb2
Oct 18 14:20:55 cherubim kernel: Attached scsi disk sdb at scsi2, channel 0, id 0, lun 0
Oct 18 14:20:55 cherubim kernel: md: bind<sdb1>
Oct 18 14:20:55 cherubim kernel: md: bind<sdb2>
Oct 18 14:20:55 cherubim kernel: md: could not bd_claim sdb1.
Oct 18 14:20:55 cherubim kernel: md: could not bd_claim sdb2.
Oct 18 14:20:57 cherubim esmith::event[3652]: Running event handler: /etc/e-smith/events/bootstrap-console-save/S03conf-hostsdb
Oct 18 14:20:57 cherubim esmith::event[3652]: S03conf-hostsdb=action|Event|bootstrap-console-save|Action|S03conf-hostsdb|Start|1287426057 561648|End|1287426057 642224|Elapsed|0.080576
Oct 19 19:53:30 cherubim kernel: SCSI device sdb: 1953525168 512-byte hdwr sectors (1000205 MB)
Oct 19 19:53:30 cherubim kernel: SCSI device sdb: drive cache: write back
Oct 19 19:53:30 cherubim kernel: SCSI device sdb: 1953525168 512-byte hdwr sectors (1000205 MB)
Oct 19 19:53:30 cherubim kernel: SCSI device sdb: drive cache: write back
Oct 19 19:53:30 cherubim kernel: sdb: sdb1 sdb2
Oct 19 19:53:30 cherubim kernel: Attached scsi disk sdb at scsi2, channel 0, id 0, lun 0
Oct 19 19:53:30 cherubim kernel: md: bind<sdb1>
Oct 19 19:53:30 cherubim kernel: md: bind<sdb2>
Oct 19 19:53:31 cherubim kernel: md: could not bd_claim sdb1.
Oct 19 19:53:31 cherubim kernel: md: could not bd_claim sdb2.
grep from /var/log/messages
Disk /dev/hda: 250.0 GB, 250059350016 bytes
Disk /dev/sda: 1000.2 GB, 1000204886016 bytes
Disk /dev/sdb: 1000.2 GB, 1000204886016 bytes
Disk /dev/md1: 106 MB, 106823680 bytes
Disk /dev/md2: 1000.0 GB, 1000095219712 bytes
Disk /dev/dm-0: 994.5 GB, 994553364480 bytes
Disk /dev/dm-1: 5536 MB, 5536481280 bytes
Disk /dev/sdc: 1083 MB, 1083801600 bytes
If I want to redo the process I assume I'd have to do a fresh install. Correct?