Have you tried something like OE Freebie Backup. I can't really comment on its performance because I've never used it personally. I do have a program called Genie Backup Manager which backups OE mail and it works very well.
I don't think you can physically access the email, they are saved in a format that OE recognises. I've forget where they are saved but the program I mentioned should do the job.
OE creates .dbx files that windows can't open but there are programs made to do so. Here are a few, the last one might even be free, I.ve never used any of them but did research try to get a deleted e-mail once.
Being a "delete freak" now I periodically search for .dbx and delete all these files. OE recreates new folders upon startup.
Right click on your folders and click on properties. THe path of the folder can be seen. Copy that folder and keep it for restoring purposes when u have to .
or you could just click+drag your mails from your inbox etc into another folder for back-up. this is what i do and always have done. when you want to take mails from a folder/cd back to your inbox, you just click+drag the files into the window that usually lists your mails :-)
I know this was a while ago Hippy but did you get your Outlook Express problem sorted? The quick answer to your question is "any installation of Outlook Express 6 can retrieve your messages - simply use the knackered hard disk as a slave, whilst you install a fresh copy of Windows onto another disk. Set up Outlook Express 6 on the new install, go to Tools > Options > Maintenance > Store Folder and point it to the directory that contains your Outlook Express files on the old hard disk and, as mentioned earlier, you can find those by searching for DBX files.
Users are sure to find in open .dbx file and dbx reader tool, simple yet versatile, to solve potential problems and stay in control of damaged dbx files in the safe folder.