Oddly the first drive appears to have been a troubled initial build in that it had 104.89GB unallocated and a rebuild from scratch (starting with bigdisk_v6 etc) on it's own, didn't clear that.

I removed it and manually cleared all partitions and then rebuilt it again and it came up as full size this time.

Re-assembled it as second disk and re-ran car2_c2.01_hijack.upgrade and it's now fine.

Total capacity now reported as 465GB :-)

I know I don't really need the build on both drives but it's proved handy this time as the drive with all the MP3's on were on the working drive. I'd only put 60GB on so far but that can take a while to do with a 10meg nic.

thanks for your help
Hodge

PS for confirmation:
empeg:/empeg/bin# fdisk -l /dev/hda

Disk /dev/hda: 255 heads, 63 sectors, 30401 cylinders
Units = cylinders of 16065 * 512 bytes

Device Boot Start End Blocks Id System
/dev/hda1 1 11 88326 5 Extended
/dev/hda2 12 16 40162+ 83 Linux
/dev/hda3 17 21 40162+ 10 OPUS
/dev/hda4 22 30401 244027350 83 Linux
/dev/hda5 * 1 3 24034+ 83 Linux
/dev/hda6 4 11 64228+ 82 Linux swap
empeg:/empeg/bin#
empeg:/empeg/bin# fdisk -l /dev/hdc

Disk /dev/hdc: 255 heads, 63 sectors, 30401 cylinders
Units = cylinders of 16065 * 512 bytes

Device Boot Start End Blocks Id System
/dev/hdc1 1 5 40131 5 Extended
/dev/hdc2 6 10 40162+ 83 Linux
/dev/hdc3 11 13 24097+ 10 OPUS
/dev/hdc4 14 30401 244091610 83 Linux
/dev/hdc5 1 3 24034+ 83 Linux
/dev/hdc6 4 5 16033+ 82 Linux swap