I know, I am a little bit late, but in case somebody
is still interested: I have written down the steps needed
to manually upgrade (without sysinst) a NetBSD 1.5 
system to 1.6.

Almost all of my machines have RAIDFrame mirroring, so, AFAIK,
it is only possible to upgrade manually.

I and others have used the document on several occasions, so I
think there are no fundamental bugs in it.

http://www.neverland.ch/netbsd

Feedback to improve it are always welcome.

Regards

Christoph

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Christoph Kaegi                                           kgc@zhwin.ch
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