Hardware

are you adding the 40GB drive or replacing the 20GB drive? On NT4 or W2K I use the following process to transfer drive contents. Backup all partitions with registrys to tape, install new drive and partition new drive as desired (observe size limitations), restore backup including registry to new drive, remove old drive and set new drive as primary master, now do minimal install of OS to new directory (WINNT2) to make drive bootable, edit boot.ini to Ref. restored WINNT directory. At this point you should be able to boot to the original install on the new drive and delete WINNT2 or keep it for repair purposes, as you choose.

Using Norton Ghost should be OK, which version of Ghost you are using?

If you get error "Non boot disk" try the following:

1. Make sure there is no diskette inserted during bootup
2. Do a restoration of MBR (Master Boot Record) by using a DOSbootdisk (prefer Windows 98 bootdisk) as : A> fdisk /mbr then reboot.
3. Make sure you partition is set to active.
4. Make sure the IDE cabling is correct.

After you finished the "copy as boot", did you switch the drive cables and jumpers? The new drive needs to jumpered as MASTER/SINGLE before the system will boot to it.

I would remove the seagate disk manager s/w. if you can not remove it you can use debug.exe to clear it.
Connect it again as slave then format it inside XP using disk management tool (inside Administrative tools).
Use norton ghost or drive image in windows in safe mode to copy the entire 20GB disk.
Reconnect this 40 GB as master then use an XP cd to boot to recovery console.
do this at the c:> prompt

1. FIXMBR C:
2. FIXBOOT C:
3. COPY x:\I386\NTLDR C
4. COPY x:\I386\NTDETECT.COM C
5. BOOTCFG /Rebuild

Where X is your cd drive.
Hope this do the trick