Time Machine says backup is larger then the actual disk

I recently had a HD die, I replaced it and restored from my TM back up. I then formatted the TM drive and am now trying to do a full back up however when I do I get an error saying that the back up size is 525GB but my HD is only a 500GB drive of which only 450GB are used.
I ran disk warrior on my main HD, ran disk utility to fix the disk and permissions. I formatted the TM drive and now I'm zeroing out the TM drive (hopefully that will work)
Anyone have any ideas why it would be reading the back up size wrong?
Thanks!
Message was edited by: zymosan

zymosan wrote:
I recently had a HD die, I replaced it and restored from my TM back up. I then formatted the TM drive and am now trying to do a full back up however when I do I get an error saying that the back up size is 525GB but my HD is only a 500GB drive of which only 450GB are used.
That's correct, as odd as it may seem.
Time Machine adds 20% to the estimated size of the backup, for workspace on the backup disk. That's usually not a problem, because a Time Machine disk should be much larger than the data it's backing-up; otherwise, there isn't enough room to keep old backups.
It varies greatly, of course, depending on how you use your Mac, but as a general rule, TM needs 2-3 times the space of the data it's backing-up to keep a reasonable "depth" of backups for you.
Short-term, you can "squeeze" a backup onto the disk by excluding something large (so the estimate is under about 410 GB) and run a backup. Then remove the exclusion and run another. Since the second backup will be much smaller, 20% of it will be much smaller, too, so it should fit.
Longer-term, you need a much larger HD; at least 1 TB.

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