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Mike, I've had to do this in the last, but under Linux, not Windows!
I used the "dd" tool under linux to take a sector-by-sector copy of the drive, stored this as a big file on my desktop machine and then played with that copy to do all the recovery work. This means you only have to fire the faulty drive up once to take the copy.
I guess there's something similar for Windows? You're much better off working with a copy like this than trying to use the faulty drive, in case it degrades further.
This assumes that the drive is still functional, if it's died completely then your only option may be to send it off to one of the data recovery places and have them disassemble it to recover the data.
cheers, Bird
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