Ben, I understand what you say about not being able to overwrite the database files while BE is using them, but with BE10d I never had to rename the SQL files.
Investigating further reveals the following:
1. During the DR process if you install the SQL database to the default location, it says it will install to: C:\Program Files\Microsoft SQL Server\MSSQL$BKUPEXEC
2. On my production server, the above folder does exist, and the master, model etc files are in the Data subfolder, as you'd expect.
3. However, when you do the initial, temporary installation, the SQL data actually appears to be installed in C:\Program Files\Microsoft SQL Server\MSSQL.1\MSSQL and the data files are in the Data subfolder.
I don't know whether this is by design, or just a flaw. It's not quite what I expected...
As a result, it's not surprising that there are no .mdf or .ldf files for the restored version of SQL, as they weren't put there by the temporary SQL installation.
As an aside, though this process failed to work for me for a considerable time, I think what made the difference was that I backed up the SQL Express databases using the BE SQL agent, which generated newer $IDR files.
If SQL Express is updated (such as with a service pack), would the old, default $IDR files fail to work?