Unfortunately, overlay will not be an option unless the BIOS and IDE controller support 48-bit LBA. Without 48-bit support, the highest you can go (even with overlay software) is 137GB. Take a look at the link bcastner posted above for more info.
Instead, you will need to use Ben's suggestion of limiting the drive to a size less than 137GB. Even then, it still might not work if the BIOS is extremely old. Old limits from the past include 8GB, 32GB, and 64GB. So, you might have to limit it to a size below one of those.
Kind of pointless though if there's no BIOS update available, however...
~cdogg
[tab][navy]For general rules and guidelines to get better answers, click here:[/navy] faq219-2884