Hi,
I think you should be able to do this:
1. Make the new partition of sufficient size. /dev/hd? whatever,
2. init 1
3. mount /dev/hd? /mnt
4. mv /usr /mnt (I'm not 100% sure this will preserve softlinks)
5. umount /mnt
6. umount /usr
7. mount /dev/hd? /usr
8. edit /etc/fstab to reflect the change.
9. init ?
? stands for whatever is appropriate.
no reboot.
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