In no particular order. These are things you might want to investigate for yourself. A listing here should not be taken as an endorsement. In fact, in many case I have not used the product and cannot comment on it.
A list of small Linux disties.
tomsrtbt, "The most Linux on 1 floppy disk." Tom also has links to other small disties.
The Linux Documentation Project. See particularly the "LILO, Linux Crash Rescue HOW-TO"
The Free Software Foundation's parted for editing (enlarging, shrinking, moving) partitions.
Partition Image for backing up partitions.
From the web page: "Partition Image is a Linux/UNIX utility which saves partitions in many formats (see below) to an image file. The image file can be compressed in the GZIP/BZIP2 formats to save disk space, and split into multiple files to be copied on removable floppies (ZIP for example), .... The partition can be saved across the network since version 0.6.0."
Hugo Rabson's Mondo "... creates one or more bootable Rescue CD's (or tape+floppies) containing some or all of your filesystem. In the event of catastrophic data loss, you will be able to restore from bare metal."
Bacula is a GLPled backup product which has bare metal recovery code inspired in part by this HOWTO.
The Beeblebrox Project looks promising.