Use Norton (symantec) Ghost, it will copy an exact image to a new drive but will make the new drive max size. I.e. copy a 20 gb drive to an 80 gb drive with 10 gb of data, new drive will be the same but 80 gb with 10 gb of data. Just make sure to make the drive active when you format it if it needs to be an active drive. This has worked for me many times, I keep a clean install of XP on a drive with all the programs I use installed so if I crash a hard drive (being stupid) I can ghost it and be up and running in a couple of hours instead of a couple of days.
Hope this helps...
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