I believe you have the steps right.
-Export the config from the old box
-install SPLAT on the new box.  Obviously, the new box needs to be in an
isolated network to avoid IP address conflicts.
-configure the interfaces and IPs to match the old box
-configure the other items you mentioned.
-import the config off the old box
-you may need to fix the licenses.  I've had to putty in to the new box,
delete the old licenses, and add the new ones again.
-make sure your Smart Gui clients will connect.
-test everything, then take the old box off line and put the new one on.

I practiced a bunch in the lab before going live.  If you do that, you
will generate lots of documentation and experience useful for DR
purposes.

Don't forget that you have to upgrade your NG AI licenses to the newer
NGX format.

-----Original Message-----
From: Mailing list for discussion of Firewall-1
[mailto:[EMAIL PROTECTED] On Behalf Of John
Lindblom
Sent: Monday, April 16, 2007 12:53 PM
To: [email protected]
Subject: [FW-1] SecurePlatform R54 to R65 upgrade

I'm going through an upgrade from NG AI R54 SPLAT on old hardware to R65
SPLAT on new hardware and can't find any real good information on the
upgrade, I have the R65 Upgrade Guide but that is not really clear.

On the old hardware I did create an export file w/R65 utility and used
TFTP
to get the file off the box.  Now on the new server during the beginning
of
the SPLAT install it is asking to configure the network interface, I'm
assuming I need to configure at least the external interface for the
install.  Once the initial install is complete I apparently have to
configure the Host name, DNS servers, the remaining NIC interfaces,
routing
and the other stuff to match the R54 configuration and then import the
R54
configuration.  I'm assuming this is also the procedure for recovering
from
a failure with a fresh install and a recent Export file.  I need to get
the
correct procedure documented for DR.

So what it comes down to is the Export file does not include any of the
SPLAT configuration, this is all reconfigured so good documentation is
very
important.

John

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