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Is there anything in the log file? Was the failure when you used the Clone 1 disk to attempt to make Clone 2? If so, there may be an issue on the Clone 1 disk and I would run chkdsk /r on all the partitions on it; this will ensure there are no bad clusters. Use Disk Management to temporarily assign drive letters to those partitions without them.
IIRC, you can boot up the V6 rescue disk and try the clone with it - its, IIRC, because I've never done it but assume "Clone" is there. You can make an image of the whole disk with V6 or 7 and restore it to desired disk - clone isn't the only way to make a duplicate disk.
BTW, formatting a partition is a waste of time. Formatting these days is nothing more than setting up a filesystem and it is all overwritten with the filesystem from the source disk either during cloning or restoring an image. However, if you do a Full Format, the disk will get a read-check of all the sectors and for large partitions this will take some time. The read-check obviously will give some confidence the disk is good but the formatting will be overwritten.
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