Time machine transfer troubles

Numerous attempts fail. Data Rescue program clone the drive. Browsing the Time machine works with either drive.
Neither drive transfers to a fresh drive.
Using Lion on an iMac. Two Buffalo branded external drives. One 500 GB, the other 1 terabyte, approximately 470 GB of data on the 500 GB in Time Machine backups. First attempt using superduper, it fails. Then I try Disk Utility. It fails. (input/output error, the console log says) Carbon Copy Cloner in block mode fails indicating bad sector blocks. OK. So I use Data Rescue and make a clone of the 500 GB drive onto the 1 Terabyte. All the data is safely in two places. But now the one terabyte thinks it is 500 GBs in size with only 30 GBs left.
Purchase a 2 TB Western Digital, try to use Disk Utility to copy (restore) the Time Machine from the 1 terabyte clone. It fails with the same input/output error. Carbon Copy Cloner in block mode fails as well. Then re-tried the original 500 GB drive to the 2 TB Western Digital. All attempts fail.
Any suggestions of how else I can transfer his data to the larger drive so that he can continue his backups? Forgetting about the backups is not an option, he is in litigation and foresees the need for some of the historical record.
Here is informative console log:
2012-01-31 18:15:05 -0800: Restore Disk
2012-01-31 18:15:05 -0800:           Source: “Time Machine Backups”
2012-01-31 18:15:05 -0800:           Destination: “Time Machine Backups1”
2012-01-31 18:15:05 -0800:           Erase Destination: Yes
2012-01-31 18:15:05 -0800:           Erase “Time Machine Backups1” and copy the contents of “Time Machine Backups” to it.
2012-01-31 18:15:05 -0800:
2012-01-31 18:15:05 -0800: Starting Restore…
2012-01-31 18:15:05 -0800: Validating target...
2012-01-31 18:15:05 -0800: done
2012-01-31 18:15:05 -0800: Validating source...
2012-01-31 18:15:05 -0800: done
2012-01-31 18:15:07 -0800: Validating sizes...
2012-01-31 18:15:07 -0800: done
2012-01-31 18:15:11 -0800: Restoring
2012-01-31 18:31:00 -0800: Could not restore - Input/output error
2012-01-31 18:31:00 -0800: Could not restore - Input/output error
2012-01-31 18:31:00 -0800:

Paul Cartwright1 wrote:
Carbon Copy Cloner in block mode fails indicating bad sector blocks. OK. So I use Data Rescue and make a clone of the 500 GB drive onto the 1 Terabyte. All the data is safely in two places.
All the data may be there, or it may not.   Whatever was on the bad sectors most likely didn't get transferred, so the backups are incomplete. The I/O errors tend to confirm that -- part of a file or files (or entire files) may be missing.
You cannot successfully copy corrupted Time Machine backups.
You can try repairing the backups, per #A5 in Time Machine - Troubleshooting. If that's able to repair them, you may be able to copy them.   That will take a very long time, at best.
But your best bet is probably to just let Time Machine start fresh on the new, empty drive.
You can still view and restore from the old backups, although you'll have a problem if you happen to hit the damaged file(s), via the Browse... option, per #E2 in that same link.

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ckuttner wrote:
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