Hi Russ, thanks for your input.
Yes, it's a WD1600 caviar se model. I was fairly certain that my efforts to unjam it would be fruitless, I was at the computer when it first spat it. It slammed to a halt with a loud screech!! [ouch - that's gotta hurt!]
It was my D drive, so the computer still works fine, just lost the data on D. Not to serious, many things that were on D are also on other external drives.
Yes, performance is a lead indicator and is something I'm paying close attention to.
I'm also mindful of the fact that if the drive does fail at some point, that it won't necessarily be that step that caused the failure, as the repeated exposure of the drive internals to the outside world [my environment is clean, but not level 10 clean] may eventually cause the drive to fail anyway.
Your comment about a deliberate mistake is spot on! That's exactly what I had planned, to first see if I can completely dismantle and reassemble being as careful as possible and if successful, to then see how 'brutal' I can get with it and still succeed.
My 3 main areas of concern are contamination, head protection and alignment of platters. The platter alignment is the biggest nightmare of them all, there's no getting 'brutal' with that, it has to be perfect or it's a bin job!