*Long Post* Help avoid plan E (windows server 2003 DR)?

I hope someone can come up with something, before I go back tomorrow, to
avoid trying plan E. As in right before plan F for fail.

Five year old IBM X225 with ServeRAID 6i running Windows 2003 Standard
and TrendMicro Officescan.

The system had a disk fail Monday. By Wednesday when we went to replace
it the Hot Spare still showed "Rebuilding" but with no disk activity light.

I marked the Hot Spare as Defunct also and the system started to rebuild
on the Standby Hot Spare.

After the rebuild I replaced the original failed unit and the system
kicked into a Copy Back.

Just about the time it had finished the Copy Back the server BSOD'd.
After that no mater what I tried it either BSOD'd or reported that it
couldn't boot.

I finally gave up, as I had checked on a valid backup before the BSOD,
and used the utility to put the ServeRAID back to default. That meant
all the drivers were now in ready status and no virtual drive.

I booted the ServeRAID utility CD and setup the RAID-5 set, Hot Spare,
Standby Hot Spare and the virtual drive.

I booted the IBM Server CD, set up the NOS partition (BTW I used a
larger than the default size as it was needed before) and installed the
basic Windows 2003 Standard.

After booting into Windows I installed the driver for the added StarTech
SCSI card (for the tape drive due to a conflict when it shares the
ServeRAID card and using BAB) and formated the rest of the virtual drive
then rebooted.

Then I installed CA Brightstar Arcserv Backup (BAB) 11 CD.

After retrieving the contents of the good tape (merge in BAB) I told it
to restore everything including the registry and AD with full overwrite.

An hour and a half later it reported that everything was restored and it
needed to reboot to apply the changes to the C drive. YEAH!!!

After the Windows splash screen from the reboot it BSOD'd with
PROCESS1_INITIALIZATION_FAILED Stop 0x000006b (0x0000007a, 0x00000008,
0x00000000, 0x00000000). Same thing with safe modes. BOO!!!

Google results are mostly for XP and point to Go Back, neither part of
this case.

At this point plan E is to reinstall Windows and BAB again but this time
only restore the user data from the tape and go for a complete manual
reconfig of Windows, users and client PCs.

Roger Vicker, CCP