Disk Restore Resize/Boot Issue

Let's start with content of MBR and boot sector of the system partition from good system (original, clean installation on 2gb cards (if possible) ) and bad, nonbootable systems (volume-restored with resize to 2 gb cards, 'disk'-restored to 2gb cards retaining 1gb size). If http://kb.acronis.com/content/14486 (from bootable media) can provide it, you can use it, if not - screenshots from some kind of disk editor/viewer, maybe with these cards plugged in other live system. Is there some boot code in sectors between MBR and the first partition (sectors 1-63) ? Does the 'data' card affect boot process at all - if you restore the 'boot' card only (using Echo or just take the original one) and the 'data' card is not plugged at all, does it boot beyond blinking cursor?

What your asking is pretty much over my head. All I know is this problem doesn't exist in the Echo series. I can resize with no issues and boot fine. I create all images on 1GB CF cards. If I restore to 1GB cards, everything boots fine. If I use the same image as I did it in the Echo series, I cannot get the larger cards to boot when I restore by Disks or Volumes (resize or default settings). The data disk is not dependant on Windows booting and the backup/restore is done in system (not with a media card reader, although the results are the same). The rescue media also does the same thing. The reason why I need resizing to work is because we cannot guarantee that we can provide the same size cards at a later date. Typically cards smaller in size get no longer produced and we have to provide the next size up at a reasonable cost. If we provide ABR10 as an aftermarket backup/recovery solution, it doesn't work, thats we downgrade to Echo. But as of the end of this month, we cannot get Echo from Acronis due to ABR11 release and the 2yr support period is expired. I do have cases pending, but Acronis is very slow on fixes.