This is actually a straightforward procedure and can be done with your system up and running. I recently had a disk in my LVM began to fail and I needed get all of the data off of it. I connected another drive and added it to the volume group (pvcreate followed by vgextend). Then I got the LVM to move all of the data off of the bad drive (pvmove) and then dropped that drive from my volume group (vgreduce). I was able to do all of this with the filesystem live, mounted and in use.
The last time I needed to do something like this pvmove would only work if the new drive that was added was the same size or larger than the one failing. So adding 2 80GB drives to rescue the data from one failing 120GB drive didn't work. Sure, I could have done fancy tricks like RAID0'ing the 80GB drives then adding _that_, but the complexity would have made things even harder to fix later on if there were issues.
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