I picked up my 20GB replacement from Fedex today. Toshiba was nice enough to honor their warranty and send me a replacement.

I swapped it into my media laptop and booted up Debian Installer. I walked through the installation and recreated my LVM configuration at which point I saved my changes and aborted the installer. I copied rsync across the network and used it to restore the whole system from backup. I then chroot‘d into the install and recovered my lilo boot block.

It’s working perfectly after working out the few kinks in the recovery process from the last bare metal restore session.