> First thought...are the partitions in similar /dev/hd?x
> e.g. /boot on both in /dev/hda1 and /dev/hd?1

Other than the size increasing (the new drive is bigger :> ), the 
partitions otherwise line up.  IE / on old disk /dev/hda1, / on new disk 
is /dev//hd?1

> 
> second thought...can you boot CD and use linux rescue mode to mount the
> partitions and chroot before you install grub?
> 
> third thought...when you installed grub, you installed to hd1 which
> would suggest the first hard drive located after the primary
> master...did you switch hard drives around so that it would now fail? If
> so, could you do the CD, chroot and install grub again?
> 

Hmmmm.... havent tried the chroot angle.  I will give that a shot when I 
get in the office tomorrow.

scott