What size hard drive did the BIOS see it as before you upgraded? I'm guessing around 127gb. If so, what happened is the OS finally trampled over that boundry enough, and probably wrote data to a critical area of the drive accidently, like the partition table area. If it did this, it may be recoverable by using a tool to rebuild the partition table manually, without blanking out the drive. I'm not sure if recreating the partitions in FDISK or silmiar will be good enough, and this is assuming the partition stuff is the issue anyhow.

The recovery utility running now, is that writing it back to the drive, or to another drive? If it's writing it to the same drive, other recovery methods may fail, as it could be trampling over needed recovery information.