Hi Robb, the process is just as explained in my post.
The failed disk has servo problems. So with lots of retryes i managed to recover the full /var and /usr, except for the ibdata1 file, wich had a bad cluster next to begining of file. To read the remaining file, i used (from the same folder)
ddrescue ibdata1 /home/temp/ibdata1.bck
This copyed good cluster anf fill unreadable cluster with 0.
I installed a virtual machine with a fresh zentyal 2.2 (same version as failed server), configured mail, zarafa and users same way as failed server.
Then i stopped zentyal and mysql and replaced /var/lib/mysql and /var/lib/zarafa folders with the recovered ones.
At this point, there was an error in zarafa logs about bad credentials to acces zarafa mysql database. I fixed this by editing a file (cant remember name).
Zarafa whas then started and mail is available in webaccess.
I configured outook connector to copy all data (mail, contacts, calendar, notes...) to a local PST.
Then i reconfigured outlook connector to connect to my new server and copied all data stored in local PST to zarafa.
All this whas possible because i only need to recover 2 maiboxes. Remaining users has local mail or is not important.
I do sql dumps to backup zarafa, but for mail, daily backup is not enought.
Half-Life, after finding the damaged sector in ibdata1, y said to users that recovery is not possible, but continued with testings.
It whas an absolute surprise to find that i can start mysql and access mail.
The only explanation i can find is: there was one more database in old server and maybe the damaged part of file is for this database (im not an sql expert)...
Anyway the second database whas recovered from backup, so im up again.