We had an old CNC machine's hard-drive fail recently. The hard-drive is an old 1275MB IDE (Seagate) and there were defiantly bad sectors on it. I was able to image the contents of the drive onto a drive in my computer before it became completely unusable (I used DD, replacing all bad sectors w/ 0s). After running a couple chdsks, the SATA drive will boot off of the image. This is great, but there's one problem. The CNC machine old and requires IDE, I've attempted to copy the currently booting image off of the SATA drive and onto IDE drives numerous times in numerous ways and every time I do so the machines return that a boot device cannot be found.

Some other information:

The file system is fat32, running windows 98  
The SATA drive is an 80gb drive
I have tried copying the image to three 20gb and two 80gb IDE drives  
I have checked the jumper on the back of the IDE drives when using them

If anyone has any ideas, questions, suggestions, etc. please let me know.

P.S. I would just put a fresh install of win98 on the machine if i had the installation media (so that's out of the question). And if it comes to it, this is my last week working here, so I'll leave that to my co-worker.

EDIT: Also, I have tried using Clonezilla as well as straight up DD to copy the image to the IDE drives.