OS 10.5 cloned drive can't expand partition

On a new 500GB that is to boot up an Intel-based Mac, I ran Disk Utility and created a single 500GB Mac OS extended (journaled) partition using the GUID partition table option.  I then cloned a MacBook Pro hard drive (160GB) to it using a DiskJockey device (bit-by-bit copy without an OS).  This left me with a 160GB partition and ~340GB unused space.  When I tried to expand the partition (through Disk Utility), I got "MediaKit reports partition (map) too small.".

I tested the drive to verify that the MacBook Pro would boot from it.  Success.  I then used VolumeWorks to expand the partition.  It appeared to be successful, but the laptop would not boot from it.

Am I using the wrong parameters when creating the partition in the first place?  What do I need to do to make this work?  My client needs all 500GB available in a single partition.
MediaKit reports partition (map) too small.

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splaitAsked:
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strungCommented:
I would suggest you wipe the drive, re-intialize and repartition using Disk Utility, then clone back using the freeware CarbonCopyCloner http://www.bombich.com which is specifically designed to clone Mac drives.
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splaitAuthor Commented:
I am willing to try that in a moment.   I suspect I have chosen an incorrect parameter when formatting the drive and creating the partition.

Having seen the parameters I used in my initial question, am I setting things up properly?
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strungCommented:
Your initial parameters that you used to initialize and partition the drive were correct provided that your Mac has an Intel chip and not the older PPC chip. (Check by pulling down the Apple menu to About This Mac). I suspect that Disk Jockey overwrote some of that information. That is why I suggest you re do the initialization and this time use CarbonCopyCloner which is designed for Macs.
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strungCommented:
When you use Carbon Copy Cloner, make sure you tick the "make bootable" box.
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splaitAuthor Commented:
I just stopped the cloning process (that had been running for almost an hour) to find that there is no "make bootable" checkbox that I can find.  Where is it?
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strungCommented:
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splaitAuthor Commented:
OK.  Cloning started.  It says (correctly) it will not boot a PPC Mac.  I assume that means it WILL boot an Intel-based Mac.  Looks like a very slow process, but I spent 6 hours trying to get the other procedure to work, so if it takes less than that, I'm good.

I'll let you know whether or not it works.

Thanks!
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strungCommented:
OK. Thanks. Good luck.
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splaitAuthor Commented:
That worked!  It took over four hours, but it worked perfectly.  

You are probably correct.  Something about the way the DiskJockey does its thing is not Mac compatible.  I will contact the manufacturer about that.  They say it is.
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