Seth,
I writing this from my upgraded PowerBook G4. Just to remind you, I did this upgrade with a $15 USB enclosure... I was too cheap to by a firewire enclosure.
1. Before I started, I cloned my new drive (connected via a USB enclosure) using Carbon Copy Cloner. (skip this step if you want because it did not work and took 2 hours).
2. The hardware install went very smooth. I had to use a lot more tools than the *I Fix It* guide suggested, but I didn't have any problems.
http://www.ifixit.com/GuideFiles/pdf/guide_208en.pdf
3. I placed the old 60GB drive in my USB enclosure.
After I put the computer back together and booted the new hard drive I ran into some problems... My computer was hanging on the gray screen with the Apple Logo.
4. I booted to the OSX 10.4 install CD and ran disk utility... The new drive was there, and formatted correctly but still no luck.
5. I used the *restore option in disk utility* and restored the original 60GB disk image (in my external USB enclosure) to the new 250GB hard drive (in the computer). Restore actually clones the data block by block and took about 30 minutes for 60GB.
6. After the clone, I rebooted and everything runs great!
I suspect that my original clone attempt did not work because I had a different volume name the the original drive (but I will never know).
So there you have it, a successful powerbook hard drive replacement with a USB enclosure.
Message was edited by: dougrs