Phew! All done, and working

So the story was:
1. Upgrade 7.6 to 8.1 using yum failed half way through. This left the server in a messy state, only half working.
2. Console backup to external hard drive took 36 hours for ~400Gbyte of data. Most of the file data was in the form of images, so it did not compress well. Backup to console writes the complete backup to the internal drive first, so make sure you have 50% free disk space. If you don't, take some files off the ibays, and remove Recyle Bin files.
3. The backup file did not transfer to the external drive once it was complete, probably because of the indeterminate state the server was in. smeserver.tgz was copied manually. Don't forget to format your external drive using ext3 to keep things simple.
4. Reinstalling SME8.1 (64 bit) from DVD just works, and that asks you if you want to restore a backup at the end. Just say "yes" and plug in the drive. This tool ~12 hours for the 300Gbyte tgz file, expanding to ~400Gbyte of files and emails.
5. The restored server had everything there, ready to go. Also 130+ yum updates to run.
6. Finally I removed the partitions from one of the old RAID disks (keeping one RAID disk aside with the old server on) and plugged it in. The "manage RAID" option in the console asks if you want to use it as a mirror - just say yes and it will sync up.
7. There will be a few contribs to install, but I aim to keep this server as lean as possible. Many years ago, when MySQL 3 and PHP 4 were cutting edge, it was a development server too. Web development tools have shot ahead these days, so development is done elsewhere, and the SME Server just handles emails and files, and nothing else.
That's it (apart from the backup strategy to put into place). Hopefully this will be useful to others stuck in this situation, with a broken server that still boots enough to do a backup. I'll try and get a few of the warnings and gotchas into the docs.
One last note - we used a free Zoho account to handle email while the server was offline. Now our server is back, I've kept the Zoho account as a backup MX. It is not a proper backup mail server, that would normally forward on the messages when your SME Server comes back online, but it's good as a free server to at least catch emails that may otherwise be lost when your broadband is down.