Hung during Tech Tool Pro volume rebuild- what to do?

Working on my ex's messed up 2007 MacBook 2.2ghz OS 10.5.8.
Extreme heat problems, was hanging a lot, and Disk First Aid failed immediately with volume errors. With some diffculty, i got his critical files backed up to an external drive (he had no backup... i have no comment) and booted it with Tech Tool Pro 5 -retail DVD, not the applecare version- with OS 10.5.7 and it also immediately found trouble with the disk directory, tho the SMART parameters were all PASS except for internal temperature (which has been high enuf to warp the bottom of the case).
But when i clicked Run Volume Rebuild, it hung in Acquiring Directory Structures. TTP's Elapsed Time clock stopped at 07:18... an hour ago. Fan is running like crazy.
does this indicate what i think it might... a non-repairable hard drive?
meanwhile, how do i get out of the TTP volume repair hang, pref without further damage? (HD was at least mounting and files accessible)
clicking the "X" to stop it just makes it "tink" with no change.
Trying to quit TTP causes an endless "canceling running jobs" loop.
Should i just force shutdown and call it a day?
He will probably buy a new Macbook rather than replace the drive in this one, and it'd be nice if the apple store could migrate directly from this drive ... unless it's really easy to migrate across two generations, leopard to lion, from the Time Machine backup i got on an external drive after the internal drive was already having trouble...? (i've never restored or migrated from Time Machine).

The Protection module of the Safety suite saves directory structure information from each of my four drives to each of the four drives. The Diagnostics module checks the volume structures of each of the drives, and the Smart module runs the SMART routines to check each of the two compatible drives for any impending troubles.
When I asked whether I could be assured the new version wouldn't behave the same way, the reply I received was:
"There are very few reports of problems with the features configured in the TechTool Protection system preferences pane as of version 5.0.7. The previously-reported problems were difficult to reproduce, and solving them required a substantial rewrite of the code in earlier versions in the TechTool Pro 5.0.x series."
I'm not convinced that was a 'yes.'
Your iCal idea sounds interesting, but keep in mind that the Safety suite of modules are within the Tech Tool Pro application itself and, when automatically launched, run in the background without the main application itself launching. Meaning, that iCal might launch Tech Tool Pro at the correct time, but will it launch the modules within?

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    taken from here:
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