Use the Forge 4 Rebuild Kit to rebuild PlateSpin Forge from version 1 to version 2. Before you begin this process, make sure that you remove any USB drives from the hardware appliance and have your ESX 4.1 license available (the older ESX 3.5 license will not be valid after you upgrade).
At a high level, the Forge 4.0, Appliance Version 2 rebuild process consists of the following major steps:
(Conditional) Re-creating the RAID array on the appliance
Setting up the system BIOS
Re-installing the hypervisor
Re-deploying Forge software (including the Forge Management VM and the Forge Appliance Configuration Console (Forge ACC)
Re-licensing all components
NOTE:The rebuild process erases all data in the Forge appliance's local storage.
If you need only to revert the appliance to its factory default state, use the Factory Reset feature that the appliance ships with Forge 4.0. See Resetting Forge to Factory Defaults
in the PlateSpin Forge 4.0 User Guide.
The complete rebuild instructions that are in this section should be used only when Factory Reset is not working or is not applicable (for example, after a major hardware failure that prevents Factory Reset from working, or when you are upgrading from an older version of the appliance).