The problems I can think of now:
1. When you copy the form (Let's call it Form2), you have to copy both pas and lfm files - Form2.pas and Form2.lfm. Did you do it?
2. Perhaps Form2 uses other units from the old project which it can't find in new project. You should copy these files too.
3. Old project might be dependent on some package and Form2 uses units from this package. New project does not have these dependencies, so it does not know where to look for these units. This can happen when you add components from Component palette (old project automatically includes the package where these components are located, but in new project this package has to be added manually).
4. Something else.
