Well, I´ve got around to setting up the development servers in the office, distributing the development files and databases across them and set up the backup routines. I´ve also changes all the files to take into account the server move so all I need to do now is set up the new servers, move accross and test.
The move and testing are pretty simple since it´ll just require taking down the database at a certain point, moving the files accross and bringing it live again. As long as I do this at stupid-o-clock then nobody should loose any info or even notice.
The main problem is the DNS shift. If I was moving to another host then this would take 24 hours and result in serious downtime, but since the same DNS servers are being used and there is just an IP address change it should go through a lot quicker. I´ll still do it at night to minimise disruption though. The only problem is that it requires going through a two minute process to change the IP address the domain points to in the control panel and we´ve got about 4,000 domains! I think I might need a sleeping bag and a lot of coffee that night!