I picked up two Cobalt RAQs. One's a 3 and the other is a 3i. My intention has been to use the 3 for Asterisk and the 3i for my main firewall. After all the round about with getting a usable image on one of them I wanted to see if I could just clone it to the other drive.
I used Ultimate Boot CD and the g4u tool. I made a backup of the working drive and that seemed to work. However, copying the backup back to the second drive kept failing on the download. So, I just did a disk to disk copy and that worked fine.
One of my concerns is that I did the initial install of Ubuntu on a 20gb drive with a 14gb partition. The second drive is 15gb. The second drive boots although there's a weird character that gets inserted during the kernel load. Not sure it matters but time will tell on that one. Hopefully I don't need to rebuild it fresh.
Lesson learned, it's easier to grow a drive than shrink it. Start with the smaller drive!