Creating a disaster recovery plan

Recently got asked to assist with disaster recovery planning for our big upgrade

Current setup is

VCenter 5.1

ESX 4.1.0 build # 988178

2 Clusters

1 Production Pool

14 Hosts

60 VMs

Goal is to have a complete disaster recovery plan put together and demonstrate it working on my test environment I am still setting up

I typically would perform vicfg-cfgbackup command to backup our host configurations however ESX does not allow this command to function

After some research it is looking like there is no one command to run and that I have to manually backup all the files  is this right?

I do have CommVault 8.0 available as well I just need a solution/plan that will allow for a complete recovery upon failure of the upgrade.

Any help would be appreciated.

Thanks!!!