rpdom wrote:You could even dd the first part of the card (up to the end of the first partition) to a temporary file (maybe even in /run/shm - which is in RAM), then unmount /boot, swap the cards over (yes, while the Pi is running!) and dd the file back out to the new card. Then mount /boot again.
Clever. 122880 * 512 sectors (56MB) isn't going to over load RAM. Once the RPi is booted you don't need /boot mounted unless you're running rpi-update.
Here's another option:
Boot from the SDCard
pop the card out, pop a new card in
create a /dev/mmcblk0p1 partition (as above - starts at 8192, ends at 122879)
mount it as /boot
run rpi-update to populate it with 4.1.4 #807
All that's left to copy are cmdline.txt and config.txt (and initramfs if you've got one) back from the original SCard. You could stash copies of those in /tmp before working on the new SDCard.