Cloneing OS & GRUB trouble

[dave s]

I am trying to copy my OS from 40GB 5400 rpm, to a new 160GB 7200 rpm HDD. I 
have done something similar in the past but am having problems now :(

I setup the partitions and format the 160GB so that I have ...

[knoppix]# fdisk /dev/hda

The number of cylinders for this disk is set to 20023.
There is nothing wrong with that, but this is larger than 1024,
and could in certain setups cause problems with:
1) software that runs at boot time (e.g., old versions of LILO)
2) booting and partitioning software from other OSs
   (e.g., DOS FDISK, OS/2 FDISK)

Command (m for help): p

Disk /dev/hda: 164.6 GB, 164696555520 bytes
255 heads, 63 sectors/track, 20023 cylinders
Units = cylinders of 16065 * 512 = 8225280 bytes

   Device Boot      Start         End      Blocks   Id  System
/dev/hda1   *           1       19930   160087693+  83  Linux
/dev/hda2           19931       20023      747022+   5  Extended
/dev/hda5           19931       20023      746991   82  Linux swap / Solaris

Command (m for help): 


I put the 40GB and 160GB in the caddies on my wifes machine, setting the 40GB 
as master and the 160GB as slave, boot knoppix and ..

rsync -aHvv /mnt/hda1/ /mnt/hdb1/

Hey presto I get a clone of the OS files on my 160GB, all is well. I change my 
160GB to master and plug its caddy into my machine

All that is needed is to setup GRUB in the MBR so, once again from knoppix 
I ...


    GNU GRUB  version 0.95  (640K lower / 3072K upper memory)

 [ Minimal BASH-like line editing is supported.  For the first word, TAB
   lists possible command completions.  Anywhere else TAB lists the possible
   completions of a device/filename. ]

grub> root (hd0,0)
 Filesystem type is ext2fs, partition type 0x83

grub> setup (hd0)
 Checking if "/boot/grub/stage1" exists... yes
 Checking if "/boot/grub/stage2" exists... yes
 Checking if "/boot/grub/e2fs_stage1_5" exists... yes
 Running "embed /boot/grub/e2fs_stage1_5 (hd0)"...  16 sectors are embedded.
succeeded
 Running "install /boot/grub/stage1 (hd0) (hd0)1+16 p 
(hd0,0)/boot/grub/stage2 /boot/grub/menu.lst"... succeeded
Done.

grub> quit


I then take out knoppix and re-boot .... ZIP :(

The system starts then a blank screen. Nothing, no kernel loaded so no go. I 
must be doing something wrong with GRUB. All the files on hda1 are there, the 
whole OS. 

Does anyone have any idea what I am doing wrong ?

Cheers

Dave