Repeated failure when time machine files moved to bigger drive...

We are trying to copy our Time Machine archive to a bigger drive. We have done this before a couple of years ago using CarbonCopyCloner and had no serious problems. Tried it this time and it was not successful*.
We have tried this again by following both versions of Apple's directions on moving our TM archive on an external drive to a bigger drive: drag the backups.backupdb from the old TM drive to the newly formatted larger drive OR use Disk Utility's Restore to clone old to new. Both took about 2 days to copy the 1.4TB via FW800. It again was not successful*.
* By "not successful" what I mean is - the files copied over fine. Disk Utility verified the disk(s) were fine. I kept the name of the new drive the same as the old. When I turned Time Machine back on and verified that it was using the external archive disk I could go into Time Machine and flip back to to files archived almost a year ago - as expected. After TM ran for a while one of two things happened: either the entire archive was replaced by only the current files (eg: the history was nuked) OR or it errored out saying there was not enough space on the new drive (3TB - the previous one was 1.5TB) even though the drives being backed up totaled 1.4TB - as if the old archive was still there (but not visible) and a new one started.
I recall seeing a post somewhere a while ago concerning trouble moving a TM archive to a different drive and the solution was to delete a couple of invisible files, but I can not find it now.
In the spirit of Full Disclosure, more has transpired than just moving the TM archive to a different drive. The Mac was changed - though its name remained the same. Also the OS went from Leopard to Lion.
In more detail, the previous Mac was a 1st generation PowerMac G5 2x2 running Leopard with 1 System & 3 data drives (thanks to a Jive5 bracket and SATA cards) and an external Time Machine drive. The new Mac is a top-end Mac Mini Server running Lion. The data drives have been moved to external FW800 cases (awaiting ThunderBolt). The TM drive will be on USB2.
[As an engineer, I understand that this should have been done one step at a time so as not to throw too many parameteres up in the air at once, but when you get shiny new hardware it's sometimes tough to hold back...]
If no solution is forthcoming, it would not be a huge tragedy to keep the old TM as a backup backup and just start anew. It just rankles me that following directions does not yield the desired result.
Message was edited by: Notary Sojak

I wanted to use the new one for Time Machine and iTunes.  I stupidly did not partition it.
I know it's tempting to want to use all the vast space on a large drive your not using, the problem is when your hardware fails, it takes both backup partitions with it when it goes.
Have multiple copies of your personal data on separate hardware, in separate locations, using easily accessible means and maintain two copies of your personal data off the machine at all times.
Your at that stage where you need more options than TimeMachine provides, you might want to consider cloning.
With cloning you could have just cloned the entire drive to another one no sweat, also you can access the files directly from any computer, Mac, Windows or Linux machine. Plus you can boot from cloned drives and do other things, like data recovery etc.
Most commonly used backup methods

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    sohs wrote:
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