Laptop HD Ghost won't work but original drive does

[Cirrus9]

We had a laptop come in for repair (HP ze5170) and the HD was failing (a few bad sectors). We ghosted the drive and it won't boot from the ghost.
We checked the ghost and it was good but we re-ghosted anyway ( we do 10-20 ghosts a day in-house). We thought for some reason the replacement HD might be bad so we ghosted another new drive and th same thing happened.... Nothing. No boot, no beep codes, nothing.
We put the failing HD back in and it worked. It booted and the files were in tact.

The replacement HD's were the same spec and size. The original HD was an IBM 40 GB, we tried a Samsung 40GB, Western Digital 40 GB. We even made sure that the MA's were the same on the HD's.
All of the HD'sare being recognized in the BIOS properly with all of the correct specs.
We never had this kind of problem from an HP before and we have done a lot of them.

At this point we are just stumped and any help from someone with a similar or any other ideas or suggestions would be greatly appreciated.
Thanks for your help in advance.

 

[CorruptedLogic]

The original drive doesn't have something crazy like on-track installed on it does it (or any other old low level software which tricked older machines into using high capacity drives). I've seen it in the past where on track messed up a ghost. Also, you might want to try ghost in raw copy (or sector copy..whatever they call it these days!) mode..again, in the past, funky partitioning (especially on dying disks with bad blocks) has forced me to use raw copy.

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[franklin97355]

Ghost does a low level copy and the bad sectors on the original may be causing a problem when they are copied (possibly incorrectly) to the new drives.

The answer is "42"