I am trying to determine which imaging software can best take ~40 gigs of data from a larger HD (~128 GB) and create an (approximate) 40-gig image and allow this image to be installed, partition-free, on a larger-than-40-gig hard drive.
Lots of software can do that, you could even use a regular copy cycle to transfer between disks. But maybe I'm not understanding your issue.
So far, my smaller-imaged data sets seem to bottleneck the partition size of the new (larger) disks when installed.
I do not understand. Do you have a a disk image? How was that image made? Did it include empty sectors and such, or special compression?
Perhaps you need a different application to manage the diskdata altogether, e.g. something like Paragon's Hard Disk Manager 12 Suite
. They also have a more Professional version, but you may have no need for the additional features. I use their Disk Partitioning software, and it's very solid software.