Laptop wont boot, no previous issues.
Detect bad sectors with long manufacturer test. No repair tried.
About to copy files, but Computer can't even find boot partition now, and neither can Linux Hirem Boot CD.
Customer wants Laptop restored with all configurations and programs, just like was functioning yesterday. Customer needs laptop functioning by end of day for big project.
Advice for recovery?
First thing, what would you have gained if the drive completely crashed while you tested it? Yup, I read almost every sector, killed your drive and didn't even bother to copy a single sector off the drive first.
Never run a diagnostic on a hard drive unless you are 100% sure that 100% of the critical data is backed up.
Now, as to where you go from here. Have you discussed the value of the data with the client? Is it worth my lab's low end price of $280 ($350 less your 20% reseller discount) or 300DDR's $300 price? If so, you should send it out before taking any further risks with your client's data.
What I've been recently noticing is that technicians want to try everything they can first before considering sending it to a professional lab...but, usually at a higher lab price and lower recovery odds.
A professional data recovery lab you can trust to work with should be your first option and not your last.
Anyway, assuming that your client's data isn't worth $300 and you want to try it on your own, here are the steps:
1. Figure out what is failing and temporarily fix it (weak heads, PCB, firmware)
2. Get a full sector-by-sector clone with a something that can handle bad sectors, ie gnu ddrescue
3. If you want a clean bootable drive, you will have to keep fighting with the clone until it is as close to 100% clean as possible
4. Then recover the data from the clone drive
Be very careful not to clone the wrong way (had a tech call yesterday and it would appear that he completely overwrite his client's drive).
Also, be very clear to the client that everything you do from here will likely cause more damage and that by your trying, you are possibly ruling out professional data recovery or, at the very least, raising the price.
Oh, by the way, your client's expectations of time are unreasonable. But, if they are rushed, you are well advised to send it to a lab ASAP, to increase the odds of success and decrease the time to get it recovered.
Good luck