Yes, I'd set up your partitions on the new card and transfer the contents over - not try to transfer the partitions themselves over. You can use various methods to do that - from cp -r through tar -cf|tar -xf through to using cpio passthrough as mentioned above. I'm not actually aware of the difference between the last two, but the latter is newer, and pretty analogous to the tar method, so I assume it's the best.
Actually, I've just looked it up, differences are: cpio handles hard links, has better defaults (e.g. preserve timestamps) and is generally easier to use. You'll want to exclude /dev, /proc, /mnt, /tmp and /media (I'll guess that's where those permission errors in the above thread came from), and that ought to be enough to get a working copy, I think.
Thinking about it, if you've not hacked the OS too much and have half decent wifi, dumping a new 1.60 SZ on the new partition and copying your /home directory over might be the simplest and most reliable solution.
Edit: How do you mean won't boot? Are you autobooting or not? Is it picking up the kernel? Where's it falling over?
