This is the approach I'd take.
Woo-Hoo! Success!
I took my 500G drive, with about 400G of programs, off the Dish box.
Then plugged in a 1TB drive (with better cooling!) to the Dish box, and let the Dish initialize it.
Then took both drives, plugged them into an Intel computer, and booted up using a Knoppix Linux CD.
Both drives were recognized - the original drive had one partition, with a folder called DishArc - full of files. This was mounted as /media/sde2
The 1T drive had two partitions, each with a DishArc folder. One partition was 500G, the second partition was 463G or so. These partitions were mounted as /media/sdf2 and /media/sdf3. There was also a third partition which claimed to be the full 1TB capacity. (/media/sdf1) It was empty, and in fact didn't have any room on it.
I opened a terminal window, did a su, then "cp -Rpv /media/sde2/DishArc /media/sdf2.
It took a LONG time - 6.5 hours or so!
I left /media/sdf3 alone.
I then shut down Linux, plugged the 1TB drive back into the Dish box, held my breath and crossed my fingers - and powered the disk up...
Eurica! The Dish box said "There is a drive connected to your USB port, do you want to use it?" - I said yes, and it came up!
All my original 400G of stuff is all there and plays. And I now have over 500G free!
So -
1. A smaller disk can be copied to a larger disk - Yea! and,
2. doing archival backups is sure possible too.
As it was doing the extrememly slow copy I was thinking that maybe there are some cp blocking options that would make that part of the process not take so long - but at this point just knowing that I never have to worry about lossing all my programs again is good enough for me!
Hurray for Knoppix Linux, hurray for the good help from you all on this forum! In particular - thanks gms49ers!
Maybe now that I have things as I want on the 1TB drives I can do the archiving faster next time using something like Ghost or TrueImage - I'll probably give that a try. I'll let you know how that goes once I give it a whirl.