Newly-baked 160GB drive won't boot in my Series1

[ysgdhio]

The 80GB drive (Seagate ST380020A) in my Series 1 (Philips HDR112) is failing
with intermittent playback but not in the same place when I rewind.

I bought a brand new 160GB drive (Western Digital WD1600AVJB-63J5A0) and baked it successfully
with InstantCake ver 1.0e, AKA "Philips HDR/PTV ver 3.0 NetReady TurboNet/CacheCard".
However, the newly-baked drive does not boot.
On the video out jack, I see the "Starting up" screen forever.
On the RF out jack, I never get the "Almost there" screen.

When I put the old 80GB drive back, it boots, so I assume it's not the power supply or drive cable.
The new 160GB drive is *brand* new. The date code is 24SEP2010.

So, is 160GB too big for a Series 1?
Is it a drive firmware issue?
Or do I need a newer version of InstantCake?

Thanks,
Andy

[DVRupgrade]

The AVJB drives have a built-in SATA/IDE adapter that seems to be incompatible with Series1 units.

[ysgdhio]

The AVJB drives have a built-in SATA/IDE adapter that seems to be incompatible with Series1 units.
Great. Any other drives I should avoid?

[DVRupgrade]

Just go for a straight-up IDE drive.

[ysgdhio]

Just go for a straight-up IDE drive.

Is there something about the WD1600AVJB-63J5A0 that should have told me it wasn't "straight-up IDE"?

How about list of 160GB models that are known to work in the Series 1?

Thanks.