Um, you need
bootable backup - on an external or internal drive. Adding another internal drive to your Mac Pro is ridiculously easy - and then you can just clone to that. This is
in addition to your Time Machine backup. DVDs won't help you in situation like you just had - a clone would have, as you could have simply rebooted to it and carried on and/or done troubleshooting on the main drive from the clone.
Use SuperDuper, which can be set up to do an automatic backup nightly, or at whatever interval you choose, to clone to the new drive. Of course, if you prefer, you can put a backup drive in an external enclosure, but that just adds expense. (I have both internal and external drives...I have redundant backups as well; Time Machine, nightly clone and weekly clone)
Time Machine backups are great - but they're not bootable. If your main drive goes south, you're out of luck until you replace it and restore from TM. A clone can boot your Mac in the time it takes to reboot with the option key held down to select the clone instead of your normal startup drive. If you make daily backups, you'll not lose much in the even of total HD failure - and with TM as well, you'll be able to recover almost everything. Time Machine backs up everything that has changed every hour - and keeps the old files as well, so it has a valuable and different function than a clone, which is an
exact copy of your hard drive at the time the clone was made.
BTW - did the Apple techs get you to do something like what is detailed in this thread?
http://forums.macrumors.com/showthread.php?t=466696I was going to suggest reading that thread, but decided that the wipe and restore from TM might be a safer place to start.
No more room inside, I have 3-2 TB’s in there now + the 1 TB as my OS drive, I run two 1.5 TB’s as back-ups, but as I said, the only drive that I could access was the OS drive, the others were showing locked, when I would try to access them it told me I did not have permission to access, running repair permissions did not work even using the system disk that came with the computer, after restarting when I tried get info it show all disks having “custom” access, when I would try to set them to read and write it would switch back to custom? I’ll be looking for RW Blu-ray DL soon, if they make them that way, if not just RW Blu-ray! I saved the terminal instructions as well, just in case! Now that the stress level is down time to take a shower and call it a night, see you tomorrow!