QUOTE(rEs @ Jan 22 2009, 07:23 AM)

What have i done wrong / missed. I've now tried several times, serveral formats with several injecting files.
Thanks in advance
I tried the hex editing and I could not get it to work. I used the info in post #30 by thr4773r and was able to get my 120G going without any hex editing at all.
Basically:
Xplorer360 to create full image of your 20G.
Xplorer360 to extract contents of partition 3 to your PC (I skipped the cache, but I think it's okay to extract).
hddhackr -f on the 120G, create undo and flash.
hddhackr -f on the 120G to confirm.
Format 120G on your 360, will show 107G free and only 1 partition in Xplorer360.
Xplorer360 to restore your 20G image to the formatted 120G, all 3 partitions should now be present, but with the 20G hddss.bin file so it won't show proper free space.
hddhackr -f on the 120G again, (no undo, if it asks), should automatically flash 120G hdd and confirm working.
Format 120G again on 360, should now show 107G free.
Xplorer360 to move the files back onto partition 3 of your new 120G.
Good luck!