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You had the right idea by trying to recover the files from another operating system because the less you use the bad drive, the better off you are.
You might not want to be booting to it and running your OS from it while your trying to recover your stuff.
I would pull the bad drive and get the replacement drive running with an operating system if at all possible. It will really help later if the drive "dies" or get worse becuse running a data recovery tool from a working version of Windows is much better. Non of the long-filename problems you get trying to recover through DOS.
After you get the replacement drive setup, slave the old drive to it and copy the files a little at a time, maybe a gig at a time. Don't try to do it all at once because you don't want to keep having to start over.
Hotrod is right about it working better on a cool drive, if you have trouble let it rest till it's cool and try again. (or put the drive in a ziplock bag and pop it in the fridge for a while).
Start with the most important things first and if you get to a point were you can't get it to copy anymore you can install a data recovery tool and try it that way.
Best of luck Wile,
Dave
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