Lessee...
(1) Install the new drive, as master or slave as appropriate, in a vacant slot on an available IDE-chain in the motherboard. Bring up Linux.
(2) If you're using a current Linux (2.6, with udev), then the device should magically appear in the
/dev directory as
/dev/hd[a-d] depending on the position where you put the drive. (Chain-1 master=hda, slav=hdb; Chain-2 hdc, hdd.)
(3) Use
smartctl to run on-board diagnostics on the drive.
(4) Make a filesystem on the device. I suggest aggressive testing at this point for read-write errors, e.g.
#mkfs.ext3 -j -c -c /dev/hd_ (where "_" is the appropriate drive-letter).
Make damn sure that you specify the correct drive! With aggressive testing options, this could easily take all night. Time to get some sleep...
(5) Now use
parted to partition the drive. You might wish to consider putting swap-space here, or an emergency
/boot partition, and so on.
(6) After the process completes, make a temporary mount-point and mount the drive:
#mkdir /mnt/newdrive && mount /dev/hd_ /mnt/newdrive.
(7) Copy files to the new drive:
#rsync --links /usr /mnt/newdrive. (Use
man rsync to review the many options here!)
(8) Now update
/etc/fstab to mount
/usr as this new drive. Meanwhile, add another entry to point to the old partition; make a mount-point for it in
/mnt as we did earlier (with "newdrive").
(9) Now you can test your changes by unmounting and remounting .. you may need to drop into single-user mode to do this .. or by restarting the system.
Have a LiveCD handy and know how to use it in case you "tpyo" something in the fstab-file and have to edit it.
All of these steps can be done in the background while you do other things, although they will monopolize the disk I/O channels and so the system will be sluggish. The
nice command is useful, especially when you are using
rsync.
Please read the man pages carefully for all commands mentioned here, before using them! I suggest that you write down a checklist .. with pencil on a nice legal pad .. before you do
anything, and that you carefully check off each step.