Summary:
I tried every method I could think of. I really liked the idea of using the Export Manager as it was a nice way to collect all the dependencies and send it out into a nice package. I was disappointed with this method. Although small scale tests seemed to work exactly how I would expect, there were major problems when running a larger scale. After about 12 hours of run time, the ZIP or JAR (tried both) which was created seemed to be corrupt. At least from what I can tell, none of the compression tools I tried seemed to support the compression method used by Windchill.
I did not have time to troubleshoot the compression method beyond a couple of tries and 2 or three extract methods. It was looking like I was going to have to "Brute-Force" export from the workspace. I was projecting this to take about 60 hours with heavy monitoring.
I started the long process by downloading the PRTs on Friday before US labor day holiday hoping I would get the export completed by the time the users returned on Tuesday. From the workspace I exported the PRTs (not too bad, went fairly quick), then the FRMs, GPHs, and LAY files. I was not looking forward to the ASMs.
Three hours after I started the ASM download and export, I had only 8 assemblies exported. Then it came to me, I already have the content out of the system in my local workspace (SID files) I just need to move them from there. I had used a utility someone developed to help retrieve data from a corrupt workspace, why couldn't I use that to get data out of a perfectly good workspace.
I ended up using the WC FileRecovery tool developed by Ron Thellen to rename the SID files to the proper CAD file name. I was finished in about two hours and I was able to spend the holiday weekend with my family.