This example will copy /dev/sde1 mounted on /backup to /dev/sdf1 mounted on /replace and afterwards change mount point, logical volume and volume group names to the source names.
Prepare new disk
fdisk /dev/sdf
n to create a new partition, select 1 and accept all defaults
w to write the new partition table and quit
mkfs.ext3 /dev/sdf1
lvm
lvm > pvcreate /dev/sdf1
lvm > vgcreate vg_replace /dev/sdf1
lvm > vgdisplay vg_replace to check ### of free extents
lvm > lvcreate -l### vg_replace (do not use -LxxGB, use size with -l### which is number of extents)
lvm > lvrename vg_replace lvol0 lv_replace
lvm > vgcfgbackup to backup volume group configurations
lvm > exit
mkfs -t ext3 /dev/vg_replace/lv_replace
mkdir /replace
mount /dev/vg_replace/lv_replace /replace
Copy content and assign new disk
rsync -avH /backup/* /replace/
umount /backup
umount /replace
lvm
lvm > lvrename vg_backup/lv_backup lv_backup1
lvm > lvchange vg_backup/lv_backup1 -an
lvm > vgrename vg_backup vg_backup1
lvm > lvchange vg_backup1/lv_backup1 -ay
lvm > lvrename vg_replace/lv_replace lv_backup
lvm > lvchange vg_replace/lv_backup -an
lvm > vgrename vg_replace vg_backup
lvm > lvchange vg_backup/lv_backup -ay
lvm > exit
mount /dev/vg_backup/lv_backup /backup -o noatime,user_xattr
Setting up LVM on top of a Linux Software Raid
prepare the new disks with a partition (see above), do not create the filesystem yet