[jtroutma]

Sounds like a perfect situation for Ghost.

Symantec has a product called Notron Ghost 2002 that will do direct HDD to HDD cloning even across different file systems. Ghost handles FAT, FAT32, NTFS and even NTFS 64k. It can automatically clone FAT volumes to FAT32 volumes and even create image files.

It allows you to copy particians, or "clone" a whole disk sector by sector. It will automatically format the destination drive to maximum size when cloning from a smaller source and handles boot records wonderfully.

What is even better is that it is great for data recovery situations. You can sector clone a damaged/failing disk to a new one and Ghost will attempt to recover the damaged sectors automatically and skip over the ones it cant and continue the clone process.

It runs under DOS and supports long file names with no problems.