Surely, if you format your second (larger) drive with system files then copy the contents of the first to the second. Swap the two drives over so the larger is now the primary drive, it should boot up OK.
There is no real reason for you to swap the two drives around, just add your new drive to your PC and have two HDD's, proably called C&D, your CD device then becomes E.
Leave you 4Gb drive where it is and leave it as the MASTER drive on PRIMARY IDE. Make sure the new drive has it's jumpers set to SLAVE. Open up the box and screw it into place, connect the same cable that is conncted to your original HDD to the new one (with a spare socket if available), connect a power supply, close the box and switch. Go into BIOS, set SLAVE ON PRIMARY IDE to auto, save, exit and away you go. Now all you have to do is format the new drive from MY COMPUTER. If your PC is a DELL, it's even easier.
If your old drive is looking a bit cramped, move some of the files (not programmes) to the new drive. Hey presto, Robert's your father's brother. Regards
Phil
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