As it seems with all hardware issues when I deal with them, a 10 minute job turned into more like an hour.  This time the causes were:                                                                      
                                                                                                                                    
 - me figuring out how to get the drive out of the server itself                                                                    
 - me making a typo in the boot config for the new kernel                                                                           
 - me forgetting to compile the newly renamed SATA drivers in the new kernel
 - me recompiling the kernel to load in the new modules                                                                             
 - the system taking ages to boot because all the drives had to be                                                                  
   filesystem checked as the last time it rebooted was 253 days ago :)                                                              
                                                                                                                                    
Other than those minor details we're back up and going on a modern kernel and a proper backup drive.  Thanks for your patience everyone!