wires12
Backup to USB should work OK, speed depends on type of data files, USB port speed, external drive speed, CPU speed etc.
4 hrs for 260Gb seems quite quick, I would even say a longer time than that is probable, it depends on many factors, including CPU power etc.
Restore will take just as long possibly longer.
Try to do a small backup using DAR (use custom templates to customise the backup folders to say only /root), refer Howtos, in order to test your setup & procedure quickly. Backing up /root should only take a few minutes.
Did you format the external USB drive as ext3 or ext4 ?
Not sure what you mean by "ended with a non zero error", you need to provide the exact error message here.
You could search these forums for grub boot issues & IIRC the wiki Howto articles etc contain some useful information for troubleshooting & repairing boot problems.
You should troubleshoot your backup, you need to get a good backup before you can do a successful restore.
You can attach & mount a "faulty" drive in a working system (as a second drive), & then read & copy contents from the faulty drive, as long as the hardware allows you to (depending on surface defects etc). I'm sure there are some forums posts from long ago about this, & some tips in wiki articles, again read the howtos.