Are you saying that your RAID controller does not support migrating to larger drives in a RAID5/6 array?
If so, your rsync method will work. That's basically how we restore servers from backups here. Just be sure to use the -H (hard-links) and --numeric-ids options when doing the rsync. Otherwise, bad things will happen. FreeBSD uses hardlinks a lot. Without -H, the restore would be many, many, many times larger than the original.
Alternatively, if you have access to enough drive space either via external drives or network shares, you can also rsync the files off, replace the harddrives with larger ones, and rsync the files back. If things go bad, you can just pop in the old drives.
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