For sure... making new file system is out of the question. I was wondering if reinstalling irix from Inst would just update the OS files like how windows will just refress the OS related files and not affect installed apps. I have a feeling reinstalling Irix may rewrite /etc, /usr, /var etc folders and loose some files.
What I’m might do instead is reinstall Irix completely on my backup drive and test this out.
I have a spare hard drive with an earlier version of irix that I use when installing apps or messing around. If the installing of an application is successful on my ‘test’ drive, I will swap out system drives and install on the good drive.

2x600mhz R14000 Octane2 dual head V12 / V10, 7 gig Ram

2x250mhz R10000 2gig ram, MXE, Digital Video, MSCSI, Jaleo

400mhz R12000 O2, 1gig Ram AV1 - 250gig Media' raid

180mhz R5000 Indy XZ 256mb ram

200mhz R4400 Extreme…….Under Construction
Dell T7600 dual 3.5 Xeon, 512 gb ram, Quadro K6000 + Tesla k20 - DaVinci Resolve Studio Editing
Dell T5500 dual 3.2 Xeon, 72gb ram, Quadro 6000 + Tesla C2075 - DaVinci Resolve Studio Cutting
Intel i7-990x 3.46GHz Extreme 6 core / Quadro 5000 & 2 x Tesla C2075 / 24gig Ram inside an SGI 320vw case