Disk Utility: Restore no longer creates bootable images?

So I have a new hard drive for my macbook, and followed the procedure I used last time of using disk utility restore to write the current hard drive image to the new disk, with the new disk in a USB enclosure.
I have done this before, it creates a bootable copy on the new disk, swap the disks away I go.
This time however the new disk is not bootable. When starting it gets to the grey screen with the rotating white pips then dumps back to a black screen with error messages (like its trying to boot of the network).
Swapping back to the old disk boots just fine, so its a problem with the image written to the new disk by disk utility restore not being bootable.
Is this a known issue? I searched the forum with no answers, and am frustrated that its now working as I have run the image twice now at about 5 hours a go for 100GB of data so I am sure its not the copy. Straight after the copy the original disk has about 10 more files than the new disk that's just been imaged, has their been some update to disk utility in the OS X patches that means it no longer copies some key files?
Note that partition on new disk is GUID as it should be, and I don't want to re-install anything from the install media I want to use make disk utility work as designed.

I found two references that may help:
A) At http://everythingapple.blogspot.com/2007/11/use-powerpc-mac-to-create-bootable.h tml it says "PowerPC Macs use the Apple Partition Map, but this poses no problem for Intel Macs, even though Intel Macs use the GUID Partition Table. The reverse is not true however. PowerPC Macs cannot boot disks with a GUID Partition Table."
1. Open up Disk Utility and select your backup drive. Select the "Partition" tab.
2. Go to the "Options" and choose "Apple Partition Map", which is the partition type necessary for PowerPC Macs.
B) Carbon Copy Cloner - Red Dot Warning on main screen: "The target volume will not boot this computer because PowerPC Macintoshes cannot boot from USB devices."
Looks like I'll have to install the 2.5" SATA drive into my PowerPC MacMini to upgrade my system volume from 80gb to 320gb.

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