Well, what a rollercoaster that was!
Tried Acronis True Image, which sort of worked but didn't copy the 1Tb+ of data from one partition. It also made a new viewable hard drive for "system reserved". Then when booting Windows using the new drive, it wanted to repair. As the PC doesn't have any CD/DVD drive then I had to use the old pen drive trick wit BIOS but forgot to add the stick as a hard drive. By the time I had realised what I'd (not) done, I had already got rid of the windows and "system reserved" partitions.
So I went on to CloneZilla. Immediately gave up on this as I was reading that I needed to install yet more software to put the files on a pen drive.
Tried CloneHD which seemed great to begin with. Then when I saw it was going to take 17 hours, I cancelled it.
Went back to CloneZilla and got through to the setup (not in Windows). I got worried as it seemed to start doing things by itself, a lot of writing on the screen, then superseeded by yet more writing without giving me the chance to read what it was saying!
In the end, I set it going. It told me it would take about 6 hours, so I left it to it and watched Top Gear.
After a three or so hours I checked it out. The program was reporting an error saying it couldn't read some data due to the pending cycle count, which is the reason I started this whole thing to begin with.
I just accepted the error and the PC restarted into the "new" Windows.
It had cloned some of the videos (part of the 1Tb+ - not porn!) but they were all messed up. Some failed to play, others played a completely different video.
Formatted that partition, then copied the data from the old hard drive after bringing it online through Acronis Disk Director. All in all, only one file lost that couldn't copy, which has already been replaced. While I haven't gone through every file (over 3000), I am sure they will be okay.
What a mess, but a good couple of days!
Now I am just running the old drive through Western Digital's extended test program, which will take about 6 hours to complete.
I hope they will take it back and replace it, possibly for an external version that isn't powered so I can use it with my TV (my powered hard drive spins up every time I turn the TV on - annoying!). The snag? The disk is 3 years old....
Maybe Amazon will be kind enough to take it back after my efforts with WD.