I've been out of it way too long. Here's an update.
I got a new 2TB drive fairly quickly, but that was the easy part. I was trying to clone my smaller 400gb boot to the newer larger one but something just did not work right.
Crappy Bios. So after two weeks I gave it to my brother and he did the cloning himself overnight. The next morning when I got it he asked "uhhhh, why don't you upgrade to Windows7?" "because I don't wanna reinstall everything over again." "do it, XP no longer has update support".....
So 4 tries later I have Win7 running on a new 2TB boot drive. That's the good news. Bad news is that none of my awesome programs work any more and I have to spend a long time re-arranging video files and re-installing EVERYTHING and crossing my fingers that things will still work.