This is a totally different approach to addressing your core need of minimizing downtime, so I appologize now if it's a distraction...
If your end goal is to reduce the overall downtime for the appliction, can I suggest you take a look at the WebSphere Virtual Enterprise (WVE) product if you haven't already?
This is a high end version of the WebSphere Application Server Network Deployment. It has a wealth of features, but here are a few related to minimizing downtime:
1. Allows for multiple versions of your application code to be deployed concurrently;
2. Priority routing of requests through intelligent routing at the web server;
3. Proavtice administration tasks to handle conditions you can define in the JVM (think memory leak for example;)
4. SLA support
5. Dynamic clusters (brining up and shutting down JVMs as demand varies.)
As someone whose investigated the WVE product, and even been through the full Proof of Technology with IBM on site, I think it might be what you're looking for.
While each environment varies, WVE might actually be cheaper in the long run compared to building an entirely new ND cluster (depending on your topology.)
On a final note, the technology that performs the
magic of WVE is also included in the IBM Workload Deployer product... That's a whole need beast that can do some great provision very quickly!
Sorry if I sidetracked your thread. Hopefully there's some value in it for you. If you have additional questions, you might want to post a new thread asking about WVE rather than use this thread.
Erik